Mask attachment and the printed assembly#

September 23 CAD review. The revised plate uses the LCD-facing surface as its print-bed face. These images show the bracket revision before the later 80 mm support placement.

The raised upper brackets and lower locating pins were replaced by screw mounts. Upper screws pass through 2.2 mm clearance holes into 1.6 mm blind mask pilots. The lower passages incline about 19.8° to clear the LCD and retain material in the cheeks. M2×10 upper and M2×14 lower screws are provisional; the lower tip allowance is only about 0.2 mm in CAD. The separate helmet-to-mask wing attachments still need their own fasteners.

The lower plate corners were subsequently tapered from 63.2 to 51.4 mm at the bottom so they sit inside the mask silhouette. The existing mask/carrier contact and manufacturing-export cleanup remain recorded; this is not a released, fully checked print set.

September 23 CAD revision following reported tab failures in printed parts. The temporary brace remains an iteration to reconsider around the battery.

All four original lower tabs reportedly snapped or split along print layers when assembled with linkage fasteners. The revised support uses the smaller screws that worked in Part_003: 1.5 mm pilots, 4 mm deep, with rounded, flared roots. The brace has 2.2 mm clearance holes and 5.4 mm × 2.2 mm head recesses, leaving 2 mm below each head seat. These dimensions describe the revision; they do not establish a measured strength improvement.

September 23 rear-panel iteration. Bearing support width is retained while the outer corners taper; the later support widening still needs matching plate alignment.

Making space for electronics#

The September 23 review compared two centered alternatives to the existing flat fore/aft arrangement. Standing the boards on edge saves about 10 mm of height relative to the proposed horizontal stack. At the then-current 75 mm layout, an 8 mm channel between component envelopes was identified as a starting point for connector trials. The live boards remained flat; the upright arrangement is a study, not installed hardware.

The CAD uses an Adafruit PCA9685 reference model. The selected physical driver is a HUAREW PCA9685 board; the reference mesh does not establish its delivered connector positions or dimensions. Mounts must follow the actual board.

Three different fit checkpoints#

The fit report contains successive experiments. Their results apply to different battery positions and included parts, so they must be read separately.

The earlier all-frame study covered locomotion, including historical turn recordings. It did not qualify seated, lying-down or other non-locomotion gestures with the battery. Its minimum estimated ground clearance was 31.29 mm in walking/variable gait, 16.07 mm in walk–run–walk, 20.00 mm in Crab, and only 2.29 mm in Crawl. A holder beneath the bank would consume some of that space. Those figures cannot be transferred to the latest higher placement.

September 24 virtual study, before the modeling scene was widened. Cyan is the battery, orange the housing, purple a screw reference and gray a servo. The plot’s “80 mm virtual” label describes that experiment, not the later saved modeling state.

This comparison excluded Part_006, its underside shim, the temporary X brace and lower cover, while retaining the Servo006 screw references. Those exclusions make it a packaging experiment, not proof that the complete mechanism and battery fit together. In particular, a servo reference cannot simply disappear from a twelve-servo build. The current underside redesign must resolve the occupied hardware and replacement structure.

The latest one-pose adjustment lowered the bank 0.5005 mm to remove housing overlap at front-left shoulder h=17°, carrier=0°, crank=0°. It is centered between the outer support walls at Y=±40 mm. The report’s opening “75 mm” label predates the saved widening; the separate width record identifies the modeling scene as 80 mm. The single-pose result and its exclusions remain the appropriate scope for that placement.