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Published December 02, 2025 ©

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newRouter – Industrial Dual-W5500 & 4G Router on ESP32-S3

This project implements a compact embedded router architecture based on
ESP32-S3 + Dual W5500 Ethernet controllers + 4G Cat.1 modem + Wi-Fi AP.

COMPONENTS
PROJECT DESCRIPTION

[PROJECT INTRODUCTION & SYSTEM ARCHITECTURE]

This project implements a compact embedded router architecture based on
ESP32-S3 + Dual W5500 Ethernet controllers + 4G Cat.1 modem + Wi-Fi AP.

It reproduces the structure of commercial SOHO routers, but at MCU level, providing:

  • WAN/LAN separation
  • Auto role-switching Ethernet (W5500 Card0)
  • Dedicated LAN port (W5500 Card1)
  • Wi-Fi AP in independent subnet (192.168.5.x)
  • Dual Ethernet subnet (192.168.4.x)
  • 4G modem as backup WAN (PPP)
  • DHCP, NAT, bridge, and routing on ESP32-S3

Key Components

  • ESP32-S3 — NAT, bridge, PPP, DHCP, AP
  • W5500 × 2 — Dual-port Ethernet over shared SPI bus
  • EC600N / A7680C 4G Modem — USB PPP fallback WAN
  • Wi-Fi AP — 192.168.5.x subnet

Port Roles

  • W5500 Card0 — Dynamic WAN/LAN switching
  • W5500 Card1 — Always LAN + DHCP server
  • 4G LTE (PPP) — Backup WAN fallback

[DATA FLOW DIAGRAM]

LAN1(W5500-1) ──┐
           │
LAN2(W5500-2) ──┤── ESP32-S3 (NAT/Bridge/AP/PPP) ── WiFi AP
4G PPP Modem (EC600N)   ─┘

[ENGINEERING SIGNIFICANCE & INDUSTRIAL VALUE]

1) Industrial router structure replicated on MCU

ESP32-S3 successfully implements:

  • Dual Ethernet
  • Wi-Fi AP
  • 4G WAN failover
  • NAT, DHCP, DNS, routing

This positions the architecture between:
Single-port W5500 devices ↔ Full OpenWRT Linux routers

2) Dual W5500 implementation is technically rare

  • Shared SPI bus
  • Independent CS/INT/RESET
  • PHY addressing
  • Auto WAN/LAN switching

This project becomes a valuable reference for dual-port embedded Ethernet design.

3) Ideal for low-power field gateways

Applicable to:

  • Energy systems
  • Factory devices
  • Remote monitoring nodes
  • Industrial telemetry
  • Edge IoT with LTE redundancy

[ARCHITECTURE COMPARISON — TABLE]

CategoryMCU Router (ESP32-S3 + Dual W5500)WizFi630SOpenWRT Router
OSFreeRTOS + ESP-IDFEmbedded LinuxLinux + OpenWRT
Wi-Fi PHY150 Mbps150–300 Mbps300 Mbps–1.2 Gbps
Real Wi-Fi~60 Mbps80–100 Mbps100–200 Mbps
NAT Throughput10–30 Mbps80–95 Mbps90–200 Mbps
EthernetDual W5500 (100M each)1×WAN + 1×LANWAN + Switch LAN
4G BackupBuilt-in PPPExternalModel dependent
PowerVery lowLowMedium–High
CustomizabilityExcellentModerateModerate
StrengthFull control + multi-interfaceStable & provenHigh performance
WeaknessLow throughputLimited customizationBig, costly

[MARKET & STRATEGIC IMPLICATIONS]

1) Filling the “MCU router” market gap

A new tier emerges:

SPI NIC → MCU Router → Linux Router

2) Strengthens W5500 ecosystem

Demonstrates that W5500 can be used not only for single NIC but also:

  • Dual-port router
  • Field gateway
  • LTE backup edge node

3) Synergy with WizFi630S

Not a competitor.
It’s a lower-tier hardware router suited for:

  • industrial micro-gateways
  • battery systems
  • ultra-low power deployments
    while WizFi630S covers:
  • mid-tier & consumer routing workloads

Together they form a portfolio, not a conflict.


[AUTHOR SUMMARY — Condensed]

lyxer123 is an applied embedded network engineer skilled in ESP-IDF, W5500, multi-interface routing, and USB-PPP modem integration.
He successfully reproduced a commercial router-grade architecture at MCU level, including dual Ethernet, Wi-Fi AP, 4G failover, and NAT/bridge logic.
His work provides a rare, high-quality reference that expands practical W5500 usage in real embedded gateway designs.


[PROJECT INTRODUCTION & SYSTEM ARCHITECTURE]

이 프로젝트는
ESP32-S3 + W5500 두 개 + 4G Cat.1 모뎀 + Wi-Fi AP로 구성된
초저가·초저전력 임베디드 라우터 구조다.

상용 SOHO 라우터의 구조를 MCU 수준에서 그대로 재현했으며,

  • WAN / LAN 분리
  • W5500 Card0 자동 WAN/LAN 전환
  • Card1 고정 LAN + DHCP
  • Wi-Fi AP 독립 서브넷(192.168.5.x)
  • W5500 듀얼 서브넷(192.168.4.x)
  • 4G PPP 백업 WAN

까지 완전한 형태로 구현됐다.


[전체 데이터 흐름도]

LAN1(W5500-1) ──┐
           │
LAN2(W5500-2) ──┤── ESP32-S3 (NAT/브리지/AP/PPP) ── WiFi AP
4G 모뎀(EC600N)   ─┘

[ENGINEERING SIGNIFICANCE & INDUSTRIAL VALUE]

1) 산업용 라우터 구조를 MCU로 축소 구현

보통 Linux SoC(OpenWRT)에서 처리하는 기능을
ESP32-S3가 단독으로 수행.

2) 듀얼 W5500 완성형 레퍼런스로서 가치

  • 공유 SPI 버스
  • CS/INT/RESET 독립
  • PHY Address 구분
  • 자동 WAN/LAN 전환

이 조합은 실제 산업 설비에서도 유효한 고급 구조.

3) IoT 현장 게이트웨이에 최적화

  • 전력 소모 최소
  • 저비용 BOM
  • 4G 백업 필수 장비에서 강점
  • 임베디드 장비 내부 라우터로 적합

[비교 테이블 — MCU Router vs WizFi630S vs OpenWRT]

항목MCU Router (ESP32-S3 + Dual W5500)WizFi630SOpenWRT 라우터
OSFreeRTOSEmbedded LinuxLinux + OpenWRT
Wi-Fi PHY150 Mbps150~300 Mbps300 Mbps~1 Gbps
실효 Wi-Fi약 60 Mbps80~100 Mbps100~200 Mbps
NAT 성능10~30 Mbps80~95 Mbps90~200 Mbps
Ethernet듀얼 W5500WAN+LANWAN+스위치
4G 백업내장 PPP외부 조합모델 차이
전력매우 낮음낮음중간~높음
커스터마이징최고중간중간
장점완전 제어, 저전력, 4G 결합안정적 성능고성능
단점고대역폭엔 부적합제한된 수정전력·비용 부담

[시장·전략적 시사점]

  • W5500 생태계 확장: “Dual Ethernet Router” 레퍼런스
  • WizFi630S와 충돌이 아니라 포트폴리오 상호보완
  • 초소형 산업 게이트웨이 분야에 현실적 수요 존재
  • 초저전력·초저비용 라우터 시장층을 새로 창출

[AUTHOR SUMMARY]

lyxer123는 ESP-IDF, W5500, 멀티인터페이스 라우팅, USB-PPP 모뎀 통합에 숙련된
실무형 임베디드 네트워크 엔지니어.

그는 듀얼 W5500, 4G PPP, Wi-Fi AP, NAT/브리지까지
상용 라우터 구조를 MCU에서 완성도 있게 재현했으며,
이는 W5500 기반 설계의 확장성과 생태계 활용 가능성을 실제로 입증.

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