An AI-assisted RP2040 audio board that worked on first spin in 5 days

Beyondex is a custom hardware mod that brings Valve Index audio to the Bigscreen Beyond VR headset, combining an RP2040-based DAC, battery management, and mechanical integration. After two failed designer attempts, the team delivered a production-ready design in five days, replacing the IP5310 power approach with TI's BQ25185 and fitting the board to a 24 mm by 50 mm envelope. From initial contact to shipping 200+ production units took weeks, not months.