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Project Aura — Open-Source ESP32 Air Quality

Professional air quality monitor with Sensirion sensors, 4.3" touch display, and local Home Assistant integration. No soldering required.

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Project Aura is an ESP32-S3 based air quality monitoring station that brings industrial-grade sensing to the maker community. Built around the Sensirion SEN66 all-in-one sensor module, it measures PM1/2.5/4/10 particulates, CO₂, VOC, NOx, temperature, and humidity. An optional SFA30 module adds direct formaldehyde (HCHO) detection. The hardware features a Waveshare ESP32-S3 board with an integrated 4.3" IPS capacitive touchscreen (800×480), running a custom LVGL-based UI with theme customization, multi-language support, and adaptive night mode. Assembly requires zero soldering — all connections use Grove/STEMMA QT/Qwiic cables and a simple I2C hub topology. A built-in RTC (PCF8523) keeps time even offline, while barometric sensors (BMP580/DPS310/BMP581) track pressure trends for weather sensitivity warnings. Native Home Assistant integration works via MQTT Auto-Discovery, exposing 20+ entities without manual YAML configuration. The firmware includes safe boot logic and factor

Why Project Aura Exists

We live in amazing times. We use smartwatches to count steps and monitor heart rates. We scan barcodes at the grocery store to check calories. We filter our water. But why do we completely ignore the air?

We take about 20,000 breaths a day. Air is the "fuel" that enters our bodies 24/7 — yet most people have no idea what they're actually breathing.

The Problem with Commercial Air Quality Monitors

Most consumer air quality monitors are closed black boxes. You cannot verify:

  • How data is processed
  • Where it's being sent
  • How sensors are calibrated
  • Whether the device will keep working after the company shuts down their cloud

Project Aura takes a different approach: you build it yourself, the firmware is fully open source, and all data stays inside your local network.

What Does It Monitor?

Project Aura measures everything that matters for indoor air quality:

Particulate Matter (PM1 / PM2.5 / PM4 / PM10)

These aren't the dust bunnies under your sofa. PM2.5 particles are so small (2.5 micrometers) they pass through your body's protective barriers directly into the bloodstream, causing inflammation. PM10 includes larger particles like pollen and mold spores — critical for allergy sufferers.

Carbon Dioxide (CO₂)

Ever noticed your head getting heavy by midday? At CO₂ levels above 1000-1200 ppm, your brain starts to "suffocate." At concentrations above 1400 ppm, cognitive capacity drops by 50% (confirmed by Harvard studies). Aura tells you when it's time to open a window.

Volatile Organic Compounds (VOC) & Nitrogen Oxides (NOx)

VOCs come from cleaning products, paints, furniture, and even cooking. NOx primarily comes from gas stoves and vehicle exhaust. Both irritate respiratory tracts and can trigger asthma.

Formaldehyde (HCHO) - Optional

That "new car smell" or fresh renovation scent? Budget particleboard furniture, laminate flooring, and adhesives can release formaldehyde — a known carcinogen — for years. The optional SFA30 sensor detects this invisible threat directly.

Temperature, Humidity & Absolute Humidity

In winter, heaters dry indoor air to desert levels (<20% RH). Dry mucous membranes can't protect your body from viruses effectively. Aura calculates Absolute Humidity (g/m³), giving you a more accurate health risk assessment than relative humidity alone.

Barometric Pressure with Trend Analysis

Many people feel migraines or joint pain before weather changes. Aura doesn't just show current pressure — it calculates Delta trends over 3 hours and 24 hours. A sharp pressure drop is your early warning system.

Hardware: No Compromises

Main Controller

Waveshare ESP32-S3-Touch-LCD-4.3 — An all-in-one board featuring:

  • Dual-core ESP32-S3 processor
  • 16MB Flash memory
  • Gorgeous 4.3" IPS capacitive touchscreen (800×480)
  • The visual quality difference from cheap displays is like comparing an old TV to a modern tablet

The Sensor Suite

Sensirion SEN66 (Switzerland) — The heart of the system. This single module replaces an entire laboratory:

  • PM1, PM2.5, PM4, PM10 (full particulate spectrum)
  • CO₂, VOC, NOx (air freshness and chemical pollution)
  • Temperature & Humidity

Sensirion SFA30 (optional) — Direct formaldehyde measurement. If you've done renovations or bought new furniture, this sensor reveals the invisible danger.

Adafruit Pressure Sensors — Support for DPS310, BMP580, or BMP581. The device auto-detects which sensor is installed and starts plotting pressure trends.

Adafruit PCF8523 RTC — Real-time clock with battery backup. Aura remembers the exact time even when powered off or working offline. When connected to WiFi, time syncs automatically every 6 hours.

Why Sensirion?

DIY air quality monitors often use a "zoo" of cheap sensors (DHT11, MQ-135, SGP30). These sensors drift over time, cross-contaminate, and provide questionable accuracy.

The Sensirion SEN66 uses Sheath Flow technology — the sensor actively draws air through a protected...

Read more »

  • 1 × Waveshare ESP32-S3-Touch-LCD-4.3 Main controller board with integrated 4.3" IPS capacitive touchscreen (800×480), ESP32-S3 dual-core processor, 16MB Flash
  • 1 × Sensirion SEN66 All-in-one environmental sensor module measuring PM1/2.5/4/10, CO₂, VOC, NOx, temperature, and humidity
  • 1 × Adafruit SEN6x Breakout Adapter board for Sensirion SEN66 with STEMMA QT / Qwiic connectors
  • 1 × Seeed Studio Grove - SFA30 Formaldehyde (HCHO) sensor module with Grove connector (optional component)
  • 1 × Adafruit BMP580 / DPS310 / BMP581 High-precision barometric pressure sensor for weather trend tracking (choose one model)

View all 14 components

  • Project Aura: The Journey from Brain Fog to Industrial-Grade Air Quality Monitor

    21cncstudio02/06/2026 at 18:57 0 comments

    Project Aura: From Idea to Reality

    February 6, 2025

    Welcome to the first official project log for Project Aura! I'm excited to finally share this journey with the Hackaday community.

    How It All Started

    This project didn't begin with a business plan or a grand vision. It started with a simple observation: we obsess over tracking our steps, calories, and sleep — but we completely ignore the air we breathe 20,000 times a day.

    I noticed my productivity dropping in the afternoons. Headaches. Brain fog. I blamed stress and poor sleep. Then I bought a cheap CO₂ monitor and discovered my home office was hitting 1800+ ppm regularly — well into the "cognitive impairment" zone according to research.

    That was my wake-up call.

    Why Build Instead of Buy?

    I looked at commercial air quality monitors. They all had the same problems:

    • Closed-source firmware (no way to verify accuracy)
    • Cloud-dependent (what happens when the company shuts down?)
    • Limited sensor selection (usually just PM2.5 and CO₂)
    • Expensive ($200-500 for decent units)
    • Poor Home Assistant integration (if any)

    As a maker, I thought: "I can build something better. And I can make it open source so others can too."

    Design Philosophy

    From day one, I had three non-negotiable principles:

    1. No soldering required — This needed to be accessible to anyone, not just electronics experts
    2. Industrial-grade sensors — No cheap DHT11/MQ-135 clones. Real Sensirion sensors or nothing.
    3. Professional UX — No "Arduino project" aesthetic. It needed to look and feel like a commercial product.

    The Hardware Journey

    I went through three major iterations:

    Version 1: ESP32 DevKit + 2.8" resistive touchscreen + breadboard mess. It worked, but looked terrible. Cable management was a nightmare.

    Version 2: Custom PCB + 3.5" capacitive display. Better, but still felt like a prototype. Manufacturing costs would've been too high for a DIY project.

    Version 3 (Current): Waveshare ESP32-S3-Touch-LCD-4.3 + Grove/STEMMA QT ecosystem. This was the breakthrough. The integrated display eliminated cable spaghetti, and standardized connectors made assembly trivial.

    The Sensirion SEN66 Decision

    This was the most expensive component choice (around $60), and I debated it for weeks.

    Cheaper alternatives like SGP30 + SCD30 + PMS5003 would've saved $30-40. But they have problems:

    • Separate sensors = more cables, more space, more complexity
    • No VOC/NOx indices (just raw resistance values that drift over time)
    • Optical PM sensors contaminate quickly without proper airflow design

    The SEN66 uses Sensirion's Sheath Flow technology — it actively pulls air through a protected channel, keeping the optics clean for years. The VOC and NOx algorithms are calibrated against human perception studies.

    In the end, reliability won. This device needs to work accurately for years, not months.

    The UI Challenge

    Getting LVGL running smoothly on ESP32 was harder than I expected. The 800×480 display needs a ton of RAM for the framebuffer. I had to:

    • Use PSRAM aggressively
    • Optimize image assets (convert to indexed color)
    • Implement smart buffering to avoid tearing
    • Pack the Theme Studio web interface into PROGMEM

    But the result? smooth gradients, and zero lag when changing themes. Worth every hour of optimization.

    Home Assistant Integration: The Killer Feature

    I knew from the start this needed seamless Home Assistant integration. Manual YAML configuration is a dealbreaker for most users.

    MQTT Auto-Discovery was the answer. The device publishes its entire configuration on startup, and Home Assistant automatically creates 20+ entities. No configuration files. No manual setup. Just works.

    I spent weeks perfecting the entity metadata (device classes, units, icons) so everything looks native in HA dashboards.

    Going Open Source

    I wrestled with this decision. Should I keep the firmware closed and try to monetize it?

    Ultimately, transparency won. Air quality affects health. People deserve to know...

    Read more »

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Discussions

Brian Rayburn wrote 03/05/2026 at 17:56 point

Would this work with the Adafruit BMP581? currently the only BMP sensor in stock at adafruit

  Are you sure? yes | no

21cncstudio wrote 03/05/2026 at 19:04 point

Yes, the Adafruit BMP581 should work — as far as I know, it uses the same library and I2C address as the BMP580.

However, I'd recommend waiting a bit before ordering. Due to component shortages, I'm planning to publish an alternative BOM next week with more readily available parts, and I'll adapt the enclosure to fit those alternatives as well.

Better to wait and see all your options! 

  Are you sure? yes | no

Brian Rayburn wrote 03/05/2026 at 19:44 point

Excellent to hear, thank you! Looking forward to putting this together!

  Are you sure? yes | no

JP wrote 02/12/2026 at 23:34 point

Looks like a cool project! Unfortunately, some of us don't have 3D printers. Any chance a case kit would be available sometime in the future?

  Are you sure? yes | no

21cncstudio wrote 02/13/2026 at 13:19 point

That’s actually a great excuse to get an Bambulab A1 mini)

Jokes aside — I understand not everyone has a 3D printer. Quite a few people have already purchased the commercial license, so after the campaign ends I expect there will be builders offering printed cases and possibly even fully assembled units.

So even if you don’t print it yourself, there should definitely be options available later on.

  Are you sure? yes | no

Edgar.kline wrote 02/11/2026 at 17:19 point

This project is being crowdfunded on MakerWorld in parallel with being here, correct?

  Are you sure? yes | no

21cncstudio wrote 02/11/2026 at 18:35 point

That's correct! The project is running on MakerWorld crowdfunding right now: https://makerworld.com/en/crowdfunding/159-project-aura-make-the-invisible-visible

  Are you sure? yes | no

DJ wrote 02/11/2026 at 16:57 point

What would it take to add a Radon sensor as well?

  Are you sure? yes | no

21cncstudio wrote 02/11/2026 at 18:36 point

I'd love to add radon detection, but unfortunately there aren't any affordable, maker-friendly radon sensors available. Radon detection requires ionization chambers or scintillation detectors, which are complex and expensive.

For radon monitoring, I'd recommend dedicated devices like the Airthings Wave Plus or Ecosense Radon Eye RD200 — they can integrate with Home Assistant alongside Aura for a complete air quality picture. 👍

  Are you sure? yes | no

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