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      },
      {
        "file": "sd-service-cap.stl",
        "material": "TPU90A cast/precision (density allowance)",
        "density_g_cm3": 1.2,
        "solid_volume_cm3": 0.7776000000000007,
        "mass_g": 0.9331200000000008
      },
      {
        "file": "battery-retaining-belt.stl",
        "material": "TPU90A cast/precision (density allowance)",
        "density_g_cm3": 1.2,
        "solid_volume_cm3": 0.9920000000000001,
        "mass_g": 1.1904000000000001
      },
      {
        "file": "battery-foam-pad-1.stl",
        "material": "Closed-cell silicone foam (selected-density allowance)",
        "density_g_cm3": 0.3,
        "solid_volume_cm3": 2.1149700000000005,
        "mass_g": 0.6344910000000001
      },
      {
        "file": "battery-foam-pad-2.stl",
        "material": "Closed-cell silicone foam (selected-density allowance)",
        "density_g_cm3": 0.3,
        "solid_volume_cm3": 2.1149700000000005,
        "mass_g": 0.6344910000000001
      },
      {
        "file": "button-plunger.stl",
        "material": "HP MJF PA12",
        "density_g_cm3": 1.01,
        "solid_volume_cm3": 0.196082897160725,
        "mass_g": 0.19804372613233226
      },
      {
        "file": "button-plunger-cap.stl",
        "material": "HP MJF PA12",
        "density_g_cm3": 1.01,
        "solid_volume_cm3": 0.1471496220280958,
        "mass_g": 0.14862111824837676
      },
      {
        "file": "button-floating-tip.stl",
        "material": "HP MJF PA12",
        "density_g_cm3": 1.01,
        "solid_volume_cm3": 0.02553346505585058,
        "mass_g": 0.025788799706409085
      },
      {
        "file": "button-silicone-diaphragm.stl",
        "material": "Silicone40A sheet,0.6mm",
        "density_g_cm3": 1.1,
        "solid_volume_cm3": 0.28333736184894515,
        "mass_g": 0.3116710980338397
      },
      {
        "file": "rgb-lightpipe.stl",
        "material": "Optical polycarbonate",
        "density_g_cm3": 1.2,
        "solid_volume_cm3": 0.06684876113652977,
        "mass_g": 0.08021851336383572
      },
      {
        "file": "camera-tpu-cradle-liner.stl",
        "material": "TPU90A cast/precision (density allowance)",
        "density_g_cm3": 1.2,
        "solid_volume_cm3": 0.05354549999999893,
        "mass_g": 0.0642545999999987
      },
      {
        "file": "camera-front-shim-1.stl",
        "material": "Closed-cell silicone foam (selected-density allowance)",
        "density_g_cm3": 0.3,
        "solid_volume_cm3": 0.00025000000000000066,
        "mass_g": 7.50000000000002e-05
      },
      {
        "file": "camera-front-shim-2.stl",
        "material": "Closed-cell silicone foam (selected-density allowance)",
        "density_g_cm3": 0.3,
        "solid_volume_cm3": 0.0002500000000000013,
        "mass_g": 7.500000000000039e-05
      },
      {
        "file": "camera-front-shim-3.stl",
        "material": "Closed-cell silicone foam (selected-density allowance)",
        "density_g_cm3": 0.3,
        "solid_volume_cm3": 0.00025000000000000066,
        "mass_g": 7.50000000000002e-05
      },
      {
        "file": "camera-front-shim-4.stl",
        "material": "Closed-cell silicone foam (selected-density allowance)",
        "density_g_cm3": 0.3,
        "solid_volume_cm3": 0.0002500000000000011,
        "mass_g": 7.500000000000032e-05
      },
      {
        "file": "camera-rear-retainer.stl",
        "material": "HP MJF PA12",
        "density_g_cm3": 1.01,
        "solid_volume_cm3": 0.4114970487869692,
        "mass_g": 0.4156120192748389
      },
      {
        "file": "camera-window-clear-pc.stl",
        "material": "Optical polycarbonate",
        "density_g_cm3": 1.2,
        "solid_volume_cm3": 0.3795223673560586,
        "mass_g": 0.4554268408272703
      },
      {
        "file": "camera-window-adhesive-ring.stl",
        "material": "3M VHB LSE-060WF acrylic foam",
        "density_g_cm3": 0.71,
        "solid_volume_cm3": 0.09174404334846886,
        "mass_g": 0.06513827077741288
      },
      {
        "file": "flat-tpu-textile-carrier.stl",
        "material": "TPU95A (density allowance)",
        "density_g_cm3": 1.2,
        "solid_volume_cm3": 3.01270106707096,
        "mass_g": 3.615241280485152
      },
      {
        "file": "lid-perimeter-gasket.stl",
        "material": "Closed-cell 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
      }
    ]
  },
  "fabrication": {
    "rigid_parts": "MJF HP PA12; solid-volume mass basis",
    "camera_window_and_lightpipe": "Window:cut\u00d822\u00b1.2mm from RS PRO7698720 stock1mm PCsheet; preserve supplied optical faces. Lightpipe:machined/bent optical PC, polished ends.",
    "button_diaphragm": "Die-cut0.6mm VMQ40A silicone; Permabond2050 plusPOP on silicone only",
    "camera_liner": "Heat-formed0.20mm TPUfilm with0.25mm rear patch; STL shows assembled liner",
    "gasket_and_pads": "Die-cut closed-cell silicone foam to specified free thickness",
    "TPU_parts": "Flat carrier:TPU95A FDM candidate at1.6mm wall; small glands/caps/tile parts:separate cast elastomer quote, not ordinary JLC FDM.",
    "window_bond": "Die-cut3M VHB LSE-060WF0.6mm ring,OD22/ID17\u00b1.2mm; prepared/primed flat PA12land;100kPa applicationpressure and72hourroomtemperaturedwell",
    "button_parts": "PA12 MJF near-net with measured finishing and supplier small-part/sprue acceptance; machined PA12 is an unquoted alternative, not released procurement.",
    "critical_fits": "Process acceptance required:window overlap landflatness<=0.2mm and disk/ring registration<=0.3mm; measured0.6+/-0.05mm gasket gap; matched/drilled M2 axes; switch gap0.05..0.25mm set from mounted switch."
  },
  "purchased_hardware": {
    "lid": "4\u00d7M2\u00d78 ISO14580 low-head screws,4\u00d7M2ISO4032 nuts",
    "camera": "2\u00d7M2\u00d76 low-head screws,2\u00d7M2 nuts",
    "button": "SDP/SI S78CSYM030035008 Type302 catalog compression spring,OD3/free8/solid2.8mm/nominalrate1.26Npermm; receiving load/rate checks in button-spring-specification.md",
    "diaphragm": "Platinum-cured VMQ silicone40\u00b15ShoreA,0.60\u00b10.05mm; Permabond2050 with POP on silicone surface only"
  },
  "placement_sha256": "78b9603bf98ec5d4b9b2554ce17f34cf36ccb01b675c7084fea13e05bc0ad20f",
  "generator_sha256": "49507e4b8a8e2f722cb9cace03ba59841baff28b222f04543b42f3df5cd0ad8e",
  "verifier_sha256": "ae52a09f1fc8230a971b959565a82bb12dfdbfc0649257726134f8cc15431f4e",
  "source_hashes": {
    "molex-header.pdf": "87ea82c5efee1d85f640cf18fe1ff8f859a2b7c5f9a72cedd32b95113cc0e925",
    "molex-housing.pdf": "a3f07ed38948507697b11f17dcad8802c6120c390c4a2eeb5c945b877e5320cb",
    "jauch-250480.pdf": "de28483b424c917c46d01596c925326568c85192829a3a9b1b49d88de1eaa1ef",
    "sdp-si-metric-hardware.pdf": "45264fc8630e7e3b711a434412e817f6b2617568a3d6c55de4124e87c349f78a",
    "rs-pro-7698720-polycarbonate.pdf": "3ac45e9e80693079ec43c69923d604efce6eba8b3b3386091bb7772d777043c8",
    "3m-window-bond-evidence.txt": "3f5896606c41c02315ad064789a2b10f089ae7211c8d3bbab3b502f2c809a0e7"
  },
  "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"
  }
}