{ "status": "PROCESS REVIEW: nominal geometry plus explicit fabrication and acceptance stages", "units": "mm", "case_dimensions_mm": { "width": 112, "length": 104, "height": 45.5 }, "assembly_envelope_mm": { "width": 112, "length_with_window": 105.6, "height_with_flat_carrier": 47.1, "window_front_projection": 1.6 }, "mass_budget": { "method": "Exact solid mesh volume times material density; excludes any arbitrary infill factor", "density_source_PA12": "https://hp3dprint.eu/downloads/HPPA12Datasheet.pdf", "cuff_manufactured_parts_g": 74.17994563899745, "hand_tile_housing_g": 2.196418495500481, "battery_g": 100, "main_PCB_g": 24, "electronics_and_fasteners_allowance_g": [ 20, 35 ], "estimated_cuff_total_g": [ 218.17994563899745, 233.17994563899745 ], "excluded": "Textile, external wrist strap webbing, tactile sheets and external wire harness; measure completed unit", "parts": [ { "file": "pcb-clamp-pad-1.stl", "material": "Closed-cell silicone foam (selected-density allowance)", 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silicone foam (selected-density allowance)", "density_g_cm3": 0.3, "solid_volume_cm3": 0.35916691182307803, "mass_g": 0.10775007354692341 }, { "file": "hand-tile-tpu-pocket.stl", "material": "TPU90A cast/precision (density allowance)", "density_g_cm3": 1.2, "solid_volume_cm3": 1.3743699570240255, "mass_g": 1.6492439484288306 }, { "file": "hand-tile-tpu-cover.stl", "material": "TPU90A cast/precision (density allowance)", "density_g_cm3": 1.2, "solid_volume_cm3": 0.4559787892263753, "mass_g": 0.5471745470716504 }, { "file": "rigid-base.stl", "material": "HP MJF PA12", "density_g_cm3": 1.01, "solid_volume_cm3": 45.5351531315204, "mass_g": 45.990504662835605 }, { "file": "rigid-lid.stl", "material": "HP MJF PA12", "density_g_cm3": 1.01, "solid_volume_cm3": 16.833433867178943, "mass_g": 17.001768205850734 } ] }, "board": { "size_mm": [ 100, 80, 1.6 ], "bottom_z_mm": 29, "top_z_mm": 30.6, "contact_supports_xy_mm": [ [ 0, 23 ], [ 18, 80 ], [ 100, 12 ], [ 100, 43 ] ], "new_mounting_holes": false }, "case": { "outer_x_mm": [ -6, 106 ], "outer_y_mm": [ -12, 92 ], "rigid_z_mm": [ 0, 45.5 ], "wall_mm": 1.3, "floor_mm": 1.3, "lid_panel_mm": 1.3, "lid_rim_mm": 2.0 }, "camera": { "source": "FH12 EDC3-150229-11 detaila; Camthink73.002.000035 outline", "connector_xy_mm": [ 90.0, 23.95 ], "mouth_y_mm": 19.40175, "insertion_depth_reference_mm": 4.4, "contact_bottom_above_PCB_mm": 0.55, "tail_tip_y_mm": 23.80175, "flex_center_z_mm": 31.3, "head_center_xyz_mm": [ 90, -7.215064692820415, 23.05 ], "head_xyz_size_mm": [ 8.5, 6.6, 8.5 ], "head_rear_y_mm": -3.9150646928204154, "lens_front_y_mm": -10.515064692820415, "lens_normal": [ 0, -1, 0 ], "flex": { "head_length_mm": 8.5, "neck_straight_mm": 19.716814692820414, "neck_arc_mm": 6.283185307179586, "bend_radius_centerline_mm": 4, "tail_length_mm": 4, "total_flat_length_mm": 38.5, "neck_width_mm": 7, "neck_thickness_mm": 0.2, "tail_width_mm": 12.5, "tail_thickness_mm": 0.3, "twist_deg": 0, "contact_normal_at_tail": [ 0, 0, -1 ] }, "optics": { "vendor_diagonal_FOV_deg": 120, "tested_circular_FOV_deg": 120, "lens_face_radius_mm": 2.98, "opaque_cone_hits_mm3": {}, "window_clear_radius_mm": 8.5, "flat_window": { "disk_MPN": "RS PRO7698720", "disk_diameter_mm": 22, "disk_diameter_tolerance_mm": 0.2, "sheet_thickness_mm": 1.0, "sheet_receiving_thickness_mm": [ 0.9, 1.1 ], "bond_MPN": "3M VHB LSE-060WF", "bond_thickness_mm": 0.6, "bond_thickness_tolerance_percent": 15, "bond_ring_OD_ID_mm": [ 22, 17 ], "bond_land_diameter_mm": 24, "finished_land_flatness_mm_max": 0.2, "land_y_mm": -12, "land_y_tolerance_mm": 0.3, "radial_registration_mm_max": 0.3, "lens_depth_tolerance_mm": 0.2, "gasket_clearance_margin_mm": 0.4868761410050997, "tunnel_radial_extra_mm": 1.5, "tunnel_diameter_tolerance_mm": 0.3, "carrier_to_land_axial_tolerance_mm": 0.3, "tunnel_clearance_margin_mm": 0.18397459621556164, "window_edge_clearance_margin_mm": 1.0816202526793344, "nominal_front_projection_mm": 1.6, 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Coupon adhesion and splash acceptance qualify actual MJF surface." }, "bend_inner_guide_radius_mm": 3.9, "worst_depth_optical_margin_mm": 0.18397459621556164 } }, "button": { "switch_height_mm": [ 4.1, 4.5 ], "switch_travel_mm": [ 0.2, 0.4 ], "factory_adjusted_rest_gap_mm": [ 0.05, 0.25 ], "cap_travel_mm": 0.8, "factory_measured_cap_travel_mm": [ 0.75, 0.85 ], "factory_measured_installed_spring_length_mm": [ 5.15, 5.25 ], "required_compliant_tip_travel_mm": 0.6, "tolerance_cases": [ { "height_mm": 4.1, "switch_travel_mm": 0.2, "gap_mm": 0.05, "actuation_before_stop_margin_mm": 0.55, "spring_length_at_stop_mm": 4.65, "minimum_spring_length_with_stop_and_installation_tolerances_mm": 4.550000000000001, "minimum_actuation_margin_with_stop_tolerance_mm": 0.49999999999999994 }, { "height_mm": 4.1, "switch_travel_mm": 0.2, "gap_mm": 0.25, "actuation_before_stop_margin_mm": 0.35000000000000003, "spring_length_at_stop_mm": 4.8500000000000005, "minimum_spring_length_with_stop_and_installation_tolerances_mm": 4.750000000000001, "minimum_actuation_margin_with_stop_tolerance_mm": 0.3 }, { "height_mm": 4.1, "switch_travel_mm": 0.3, "gap_mm": 0.05, "actuation_before_stop_margin_mm": 0.45, "spring_length_at_stop_mm": 4.75, "minimum_spring_length_with_stop_and_installation_tolerances_mm": 4.65, "minimum_actuation_margin_with_stop_tolerance_mm": 0.39999999999999997 }, { "height_mm": 4.1, "switch_travel_mm": 0.3, "gap_mm": 0.25, "actuation_before_stop_margin_mm": 0.25000000000000006, "spring_length_at_stop_mm": 4.95, "minimum_spring_length_with_stop_and_installation_tolerances_mm": 4.8500000000000005, "minimum_actuation_margin_with_stop_tolerance_mm": 0.2 }, { "height_mm": 4.1, "switch_travel_mm": 0.4, "gap_mm": 0.05, "actuation_before_stop_margin_mm": 0.35, "spring_length_at_stop_mm": 4.8500000000000005, "minimum_spring_length_with_stop_and_installation_tolerances_mm": 4.750000000000001, "minimum_actuation_margin_with_stop_tolerance_mm": 0.29999999999999993 }, { "height_mm": 4.1, "switch_travel_mm": 0.4, "gap_mm": 0.25, "actuation_before_stop_margin_mm": 0.15000000000000002, "spring_length_at_stop_mm": 5.050000000000001, "minimum_spring_length_with_stop_and_installation_tolerances_mm": 4.950000000000001, "minimum_actuation_margin_with_stop_tolerance_mm": 0.09999999999999998 }, { "height_mm": 4.3, "switch_travel_mm": 0.2, "gap_mm": 0.05, "actuation_before_stop_margin_mm": 0.55, "spring_length_at_stop_mm": 4.65, "minimum_spring_length_with_stop_and_installation_tolerances_mm": 4.550000000000001, "minimum_actuation_margin_with_stop_tolerance_mm": 0.49999999999999994 }, { "height_mm": 4.3, "switch_travel_mm": 0.2, "gap_mm": 0.25, "actuation_before_stop_margin_mm": 0.35000000000000003, "spring_length_at_stop_mm": 4.8500000000000005, "minimum_spring_length_with_stop_and_installation_tolerances_mm": 4.750000000000001, "minimum_actuation_margin_with_stop_tolerance_mm": 0.3 }, { "height_mm": 4.3, "switch_travel_mm": 0.3, "gap_mm": 0.05, "actuation_before_stop_margin_mm": 0.45, "spring_length_at_stop_mm": 4.75, "minimum_spring_length_with_stop_and_installation_tolerances_mm": 4.65, "minimum_actuation_margin_with_stop_tolerance_mm": 0.39999999999999997 }, { "height_mm": 4.3, "switch_travel_mm": 0.3, "gap_mm": 0.25, "actuation_before_stop_margin_mm": 0.25000000000000006, "spring_length_at_stop_mm": 4.95, "minimum_spring_length_with_stop_and_installation_tolerances_mm": 4.8500000000000005, "minimum_actuation_margin_with_stop_tolerance_mm": 0.2 }, { "height_mm": 4.3, "switch_travel_mm": 0.4, "gap_mm": 0.05, "actuation_before_stop_margin_mm": 0.35, "spring_length_at_stop_mm": 4.8500000000000005, "minimum_spring_length_with_stop_and_installation_tolerances_mm": 4.750000000000001, "minimum_actuation_margin_with_stop_tolerance_mm": 0.29999999999999993 }, { "height_mm": 4.3, "switch_travel_mm": 0.4, "gap_mm": 0.25, "actuation_before_stop_margin_mm": 0.15000000000000002, "spring_length_at_stop_mm": 5.050000000000001, "minimum_spring_length_with_stop_and_installation_tolerances_mm": 4.950000000000001, "minimum_actuation_margin_with_stop_tolerance_mm": 0.09999999999999998 }, { "height_mm": 4.5, "switch_travel_mm": 0.2, "gap_mm": 0.05, "actuation_before_stop_margin_mm": 0.55, "spring_length_at_stop_mm": 4.65, "minimum_spring_length_with_stop_and_installation_tolerances_mm": 4.550000000000001, "minimum_actuation_margin_with_stop_tolerance_mm": 0.49999999999999994 }, { "height_mm": 4.5, "switch_travel_mm": 0.2, "gap_mm": 0.25, "actuation_before_stop_margin_mm": 0.35000000000000003, "spring_length_at_stop_mm": 4.8500000000000005, "minimum_spring_length_with_stop_and_installation_tolerances_mm": 4.750000000000001, "minimum_actuation_margin_with_stop_tolerance_mm": 0.3 }, { "height_mm": 4.5, "switch_travel_mm": 0.3, "gap_mm": 0.05, "actuation_before_stop_margin_mm": 0.45, "spring_length_at_stop_mm": 4.75, "minimum_spring_length_with_stop_and_installation_tolerances_mm": 4.65, "minimum_actuation_margin_with_stop_tolerance_mm": 0.39999999999999997 }, { "height_mm": 4.5, "switch_travel_mm": 0.3, "gap_mm": 0.25, "actuation_before_stop_margin_mm": 0.25000000000000006, "spring_length_at_stop_mm": 4.95, "minimum_spring_length_with_stop_and_installation_tolerances_mm": 4.8500000000000005, "minimum_actuation_margin_with_stop_tolerance_mm": 0.2 }, { "height_mm": 4.5, "switch_travel_mm": 0.4, "gap_mm": 0.05, "actuation_before_stop_margin_mm": 0.35, "spring_length_at_stop_mm": 4.8500000000000005, "minimum_spring_length_with_stop_and_installation_tolerances_mm": 4.750000000000001, "minimum_actuation_margin_with_stop_tolerance_mm": 0.29999999999999993 }, { "height_mm": 4.5, "switch_travel_mm": 0.4, "gap_mm": 0.25, "actuation_before_stop_margin_mm": 0.15000000000000002, "spring_length_at_stop_mm": 5.050000000000001, "minimum_spring_length_with_stop_and_installation_tolerances_mm": 4.950000000000001, "minimum_actuation_margin_with_stop_tolerance_mm": 0.09999999999999998 } ], "tested_poses": 324, "force_note": "Spring preload minimum 3.2 N exceeds datasheet maximumoperatingforce2.94N; maximum accepted contact force including stop/installation tolerances4.69 N requires switch overload validation.", "diaphragm": { "material": "Platinum-cured VMQ silicone", "hardness_Shore_A": [ 35, 45 ], "thickness_mm": 0.6, "thickness_tolerance_mm": 0.05, "bond": "Permabond2050; POP primer on silicone only; PA12 dried and abraded", "bond_source": "https://permabond.com/materials_bonded/how-to-bond-silicone/" }, "spring_requirement": { "OD_mm": 3, "free_length_mm": 8, "installed_length_mm": 5.2, "rate_N_per_mm": [ 1.15, 1.35 ], "preload_N": [ 3.2, 3.8 ] }, "spring_design": "SDP/SI S78CSYM030035008 catalog compression spring; receiving specification in button-spring-specification.md", "catalog_spring": { "MPN": "S78CSYM030035008", "manufacturer": "SDP/SI", "material": "Type302 stainless", "wire_diameter_mm": 0.35, "OD_mm": 3, "free_height_mm": 8, "solid_height_mm": 2.8, "rate_N_per_mm": 1.26, "ends": "squared and ground", "catalog_physical_page": 64, "catalog_source": "https://www.sdp-si.com/D815/D815-Metric-Section10-Hardware.pdf", "nominal_force_at_5_2mm_N": 3.528, "nominal_force_at_4_65mm_N": 4.221, "receiving_force_at_5_2mm_N": [ 3.2, 3.8 ], "receiving_rate_N_per_mm": [ 1.15, 1.35 ], "receiving_force_at_4_65mm_N_max": 4.55, "receiving_force_at_4_55mm_N_max": 4.69, "receiving_OD_mm_max": 3.1, "receiving_solid_height_mm_max": 2.9 }, "commissioning": "Finish tip nose to0.15mm nominal released gap; verify0.05mm minimum and0.25mm maximum with feelers against mounted switch; measure stop0.80\u00b10.05mm and installed spring length5.20\u00b10.05mm; verify released continuity and actuation before hard-stop." }, "rf": { "antenna_only_exemption": "U_MCU module contains its own antenna", "antenna_reference_overlap_mm3": 371.9169999999987, "other_conductive_overlap_mm3": {} }, 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34.05 ], "triangle_count": 512, "pieces": [ { "volume_mm3": 91.74404334846886, "bounds_mm": [ 79.0, -12.600000000000001, 12.05, 101.0, -12.0, 34.05 ] } ] }, "flat-tpu-textile-carrier.stl": { "status": "Error.NoError", "connected_solids": 1, "volume_mm3": 3012.70106707096, "bounds_mm": [ 12.0, -12.0, -1.6, 88.0, 92.0, 3.2 ], "triangle_count": 3942, "pieces": [ { "volume_mm3": 3012.70106707096, "bounds_mm": [ 12.0, -12.0, -1.6, 88.0, 92.0, 3.2 ] } ] }, "lid-perimeter-gasket.stl": { "status": "Error.NoError", "connected_solids": 1, "volume_mm3": 359.166911823078, "bounds_mm": [ -5.5, -11.5, 42.9, 105.5, 91.5, 43.699999999999996 ], "triangle_count": 562, "pieces": [ { "volume_mm3": 359.166911823078, "bounds_mm": [ -5.5, -11.5, 42.9, 105.5, 91.5, 43.699999999999996 ] } ] }, "hand-tile-tpu-pocket.stl": { "status": "Error.NoError", "connected_solids": 1, "volume_mm3": 1374.3699570240256, "bounds_mm": [ 132.5, -2.0, 0.0, 163.5, 20.0, 6.0 ], "triangle_count": 2806, "pieces": [ { "volume_mm3": 1374.3699570240256, "bounds_mm": [ 132.5, -2.0, 0.0, 163.5, 20.0, 6.0 ] } ] }, "hand-tile-tpu-cover.stl": { "status": "Error.NoError", "connected_solids": 1, "volume_mm3": 455.9787892263753, "bounds_mm": [ 138.0, -2.0, 5.3, 158.0, 18.0, 7.4 ], "triangle_count": 494, "pieces": [ { "volume_mm3": 455.9787892263753, "bounds_mm": [ 138.0, -2.0, 5.3, 158.0, 18.0, 7.4 ] } ] }, "rigid-base.stl": { "status": "Error.NoError", "connected_solids": 1, "volume_mm3": 45535.153131520405, "bounds_mm": [ -6.0, -12.0, 0.0, 106.0, 92.0, 43.5 ], "triangle_count": 16200, "pieces": [ { "volume_mm3": 45535.153131520405, "bounds_mm": [ -6.0, -12.0, 0.0, 106.0, 92.0, 43.5 ] } ] }, "rigid-lid.stl": { "status": "Error.NoError", "connected_solids": 1, "volume_mm3": 16833.433867178945, "bounds_mm": [ -6.0, -12.0, 31.1, 106.0, 92.0, 45.5 ], "triangle_count": 6440, "pieces": [ { "volume_mm3": 16833.433867178945, "bounds_mm": [ -6.0, -12.0, 31.1, 106.0, 92.0, 45.5 ] } ] }, "camera-module-envelope.stl": { "status": "Error.NoError", "connected_solids": 1, "volume_mm3": 476.8499999999999, "bounds_mm": [ 85.75, -10.515064692820415, 18.8, 94.25, -3.9150646928204154, 27.3 ], "triangle_count": 12, "pieces": [ { "volume_mm3": 476.8499999999999, "bounds_mm": [ 85.75, -10.515064692820415, 18.8, 94.25, -3.9150646928204154, 27.3 ] } ] }, "camera-flex-envelope.stl": { "status": "Error.NoError", "connected_solids": 1, "volume_mm3": 51.39911687256051, "bounds_mm": [ 83.75, -4.015064692820415, 27.3, 96.25, 23.80175, 31.45 ], "triangle_count": 540, "pieces": [ { "volume_mm3": 51.39911687256051, "bounds_mm": [ 83.75, -4.015064692820415, 27.3, 96.25, 23.80175, 31.45 ] } ] }, "battery-envelope.stl": { "status": "Error.NoError", "connected_solids": 1, "volume_mm3": 58968.0, "bounds_mm": [ 12.0, 20.0, 3.0, 84.0, 59.0, 24.0 ], "triangle_count": 12, "pieces": [ { "volume_mm3": 58968.0, "bounds_mm": [ 12.0, 20.0, 3.0, 84.0, 59.0, 24.0 ] } ] }, "battery-ntc-envelope.stl": { "status": "Error.NoError", "connected_solids": 1, "volume_mm3": 63.99999999999999, "bounds_mm": [ 24.0, 21.0, 24.0, 32.0, 25.0, 26.0 ], "triangle_count": 12, "pieces": [ { "volume_mm3": 63.99999999999999, "bounds_mm": [ 24.0, 21.0, 24.0, 32.0, 25.0, 26.0 ] } ] }, "pcb-envelope.stl": { "status": "Error.NoError", "connected_solids": 1, "volume_mm3": 12800.000000000013, "bounds_mm": [ 0.0, 0.0, 29.0, 100.0, 80.0, 30.6 ], "triangle_count": 12, "pieces": [ { "volume_mm3": 12800.000000000013, "bounds_mm": [ 0.0, 0.0, 29.0, 100.0, 80.0, 30.6 ] } ] }, "hand-tile-pcb-envelope.stl": { "status": "Error.NoError", "connected_solids": 1, "volume_mm3": 204.79999999999995, "bounds_mm": [ 140.0, 0.0, 0.9999999999999999, 156.0, 16.0, 1.7999999999999998 ], "triangle_count": 12, "pieces": [ { "volume_mm3": 204.79999999999995, "bounds_mm": [ 140.0, 0.0, 0.9999999999999999, 156.0, 16.0, 1.7999999999999998 ] } ] } }, "release_gates": [ "Inspect SDP/SI S78CSYM030035008 spring against specified5.2mm load and rate; validate released-force and4.69N overload on PTS636SK43 lots; fit captured tip nose to actual switch height.", "Measure supplied camera tail insertion and lens-depth datum against manufacturer reference drawing; fit carrier shims before glue cure.", "Measure assembled component heights against documented package maxima plus0.20mm assembly allowance; confirm actual wire bend/bundle diameters.", "Validate TPU gland compression,25percent lid-gasket compression, bonded button diaphragm and window adhesive with an assembled dust/splash test.", "Verify printed dimensional coupons, PCB thickness clamp compression, strap retention load, thermal behavior and battery assembly on built hardware." ], "placement_sha256": "78b9603bf98ec5d4b9b2554ce17f34cf36ccb01b675c7084fea13e05bc0ad20f", "first_article_fabrication_ready": false, "unresolved_design_or_process_items": [ "Obtain an accepted PA12 print-and-finish quote (broad shell faces1.3mm; local1.10mm lug wall/guide features need process-specific acceptance): aligned M2 holes/nut slots, camera datums, window seat and gasket faces need the specified local final dimensions; nominal MJF tolerance alone is insufficient.", "Confirm the small button print/sprue and finishing route, or price machined PA12 alternative. Set tip length against measured switch; inspect0.8mm diametral sliding clearances and finish spring-guide pin to<=2.05mm.", "Confirm a cast elastomer supplier for small glands/caps/tile parts. JLC FDM95A minimum30x30x15 and1.2mm walls do not cover these small thin features. Knife-split glands after casting with zero material removal.", "Confirm selected wire OD and allowed static R2.5mm bends for the PH/GH routing volumes; qualify remaining lead dressing. Battery lead route is bounded across undimensioned exits; direct leads require measured reach after crimp, otherwise use the exactR4 factory extension routes,35mm addedAWG22 per lead/5mm overlap, with assembler-qualified insulated joints and<=2mOhm per splice.", "Approve silicone foam grade and a measured compression/flatness plan for lid and PCB pads. Rear screw positions avoid RF and SD; polymer ribs stiffen the rear/left span, but seal-load uniformity across the longest113.2mm screw chord requires fixture/deflection acceptance.0.2mm gasket compression cannot be guaranteed by two as-printed mating faces.", "Quote the optical polycarbonate lightpipe and cut stock1mm PC window; prepare the flat PA12 bond land and apply specified3M Primer94/LSE060WF tape process. Full geometry/materials span several fabrication processes." ], "physical_acceptance_tests": [ "Switch return/force/overload/cycle test after measured gap setting", "Cable pull and gland/diaphragm/window dust-splash tests", "PCB pad compression, strap pull, panel/drop, temperature and completed-system mass/fit measurements" ], "jlc_process": { "PA12_tolerance_below_100mm_mm": 0.3, "PA12_tolerance_above_100mm_percent": 0.4, "case_112mm_span_tolerance_mm": 0.448, "case_104mm_span_tolerance_mm": 0.416, "minimum_wall_mm": 1.0, "quote_preflight_general_wall_mm_strictly_greater_than": 1.2, "broad_shell_wall_selected_mm": 1.3, "minimum_escape_hole_mm": 2.5, "source": "https://jlc3dp.com/help/article/pa12-hp-nylon" }, "dfm_revision": { "previous_commit": "5542e9e", "rigid_case_dimension_change_mm": [ 0, 0, 0 ], "carrier_below_case_mm": 1.6, "previous_saddle_below_case_mm": 8, "assembly_height_excluding_textile_mm": 47.1, "previous_assembly_height_excluding_textile_mm": 53.5, "button_retaining_ledges_mm": 1.0, "button_sliding_diametral_clearances_mm": 0.8, "camera_lug_OD_mm": 7.6, "camera_nut_pocket_radial_wall_min_mm": 1.1, "nut_insertion_slot_width_mm": 5.3, "powder_escape_holes_mm": 2.8, "gland_split": "Knife cut after casting, zero material removal; CAD is closed assembled condition" }, "harness": { "file": "harness-envelopes.json", "service_volumes_checked": 12, "wired_variant_removed_plugs": { "J_INDEX_wire_bends": "cable-grommet-1-blanking-plug.stl", "J_MIDDLE_wire_bends": "cable-grommet-2-blanking-plug.stl", "J_RING_wire_bends": "cable-grommet-3-blanking-plug.stl", "J_LITTLE_wire_bends": "cable-grommet-4-blanking-plug.stl", "J_THUMB_wire_bends": "cable-grommet-5-blanking-plug.stl", "J_IMU_CUFF_wire_bends": "cable-grommet-6-blanking-plug.stl", "J_PALM_HEEL_wire_bends": "cable-grommet-7-blanking-plug.stl" }, "PH_wire_OD_max_mm": 1.5, "battery_connector": { "header": "43045-0200", "housing": "43025-0200", "contact": "43030-0007", "pin1_xy_mm": [ 4.1, 66.25 ], "peg_xy_mm": [ 4.1, 70.57 ], "PCB_edge_distance_mm": 9.43, "manufacturer_edge_distance_max_mm": 10.16, "edge_tolerance_allowance_mm": 0.2, "bare_header_max_height_mm": 9.27, "assembly_allowance_mm": 0.2, "mated_profile_max_height_mm": 11.26, "rear_skirt_bound_mm": { "x": [ 1.795, 6.405 ], "y": [ 80.55, 83.85 ], "z": [ 28.6, 30.6 ], "basis": "Conservative rear skirt bound outside PCB from note7; verify supplied housing falls within audited envelope" }, "wire_exit_y_nominal_mm": 82.82, "wire_exit_y_drawing_tolerance_mm": 0.83, "wire_exit_y_assembly_allowance_mm": 0.2, "wire_exit_z_family_mm": [ 31.525, 40.935 ], "underdetermined_datum": "Wire centerlineZ and pack exitY/Z are bounded service families, not manufacturer dimensions", "wire_OD_max_mm": 1.85, "routing_axis_allowance_mm": 0.2, "minimum_reserved_centerline_bend_R_mm": 4, "external_path_length_range_mm": [ 54.668180422481306, 61.509179878066575 ], "stock_lead_mm": [ 65, 75 ], "fallback_minimum_effective_lead_mm": 95, "fallback_added_conductor_per_lead_mm": 35, "fallback_overlap_per_lead_mm": 5, "fallback_effective_gain_per_lead_mm": 30, "fallback_total_added_conductor_mm": 70, "fallback_splice_count": 2, "fallback_max_resistance_per_splice_mOhm": 2, "conservative_terminal_consumption_upper_bound_mm": 14.25, "strain_relief_slack_mm": 3, "fallback_external_path_length_range_mm": [ 62.273903599393364, 74.17444783869539 ], "fallback_worst_reach_margin_mm": 3.575552161304614, "direct_termination_acceptance": "Measured usable lead length after selected contact crimp must exceed measured routed length plus3mm strain-relief slack. Otherwise factory extension variant required.", "fallback": "Factory35mm AWG22 added per lead minus5mm overlap gives30mm effective extension; total nominal100mm; same43030-0007 contacts. Exact crimp consumption and pack exit datum remain assembly measurements." }, "battery_splice_envelopes": { "variant": "Factory extension fallback only", "insulated_max_OD_mm": 4, "insulated_max_length_mm": 16, "centers_mm": [ [ 6.5, 63, 14 ], [ 10.5, 67, 17 ] ] }, "GH_wire_OD_max_mm": 0.7, "reserved_bend_centerline_R_mm": 2.5, "lid_fasteners_xy_mm": [ [ -2, -6 ], [ 102, -6 ], [ 24, 86 ], [ 36, 86 ] ], "rear_left_lid_ribs_mm": [ 2.6, 1.3 ], "rear_left_clamp_span_nominal_mm": 95.60334722173695, "adjacent_lid_screw_chords_mm": { "front": 104.0, "left": 95.60334722173695, "rear": 12.0, "right": 113.22543883774529 }, "gasket_edge_acceptance": "Measure installed gap0.60\u00b10.05mm along entire perimeter after fasteners tightened; local lid ribs support rear-left seal, print flatness and first-article compression test required", "variant_groups": { "direct": [ "J_BAT_wire_service_family" ], "factory_extended": [ "J_BAT_factory_extension_wire_1", "J_BAT_factory_extension_wire_2", "J_BAT_extension_splices" ] }, "scope": "Variants are mutually exclusive; worst-clearance service family covers undimensioned exit heights; measured reach and assembler splice process acceptance remain explicit" } }