AnasSarkiz/muse-voice-remote

dist/assembly/enclosure/printing-and-assembly.md

# Muse Voice Remote enclosure — reference 16 mm fit prototype

The shell implements the illustrated two-piece layout: charcoal front tray and removable rear cover, teal TALK cap, side privacy/power caps, lower USB opening and rear speaker grille. Shell body: **72 × 53.5 × 16 mm**. Controls protrude: the full nominal assembly is **73.7 × 54.75 × 16 mm**. This is engineering CAD for a fit prototype, not a qualified production enclosure.

## Files and printing

Print one each of `case_front-print.stl`, `case_rear-print.stl`, `control_talk-print.stl`, `control_privacy-print.stl` and `control_power-print.stl`. The `-print` files sit on Z=0; rear cover is flipped outside-face down. Files without `-print` retain assembled coordinates, measured from the outer front surface. Units are millimetres. OpenSCAD sources accompany every STL; native tscircuit geometry comes from `design/enclosure.ts`.

Use SLA for initial small-cap/slider fit checks, or calibrated fine-layer PETG with a small nozzle. Main walls are 0.8 mm; front lip 0.6 mm; rear wall 0.8 mm. The front tray needs local removable supports below internal screw bosses and thin PCB ledges. Rear cover prints outside-face down with posts upward. Caps may need local support and careful deburring. These are not support-free parts. Keep supports away from the display lip and pilot bores. Do not scale the complete part to compensate for one tight feature.

Trial-fit the 0.15 mm lap clearance, Ø1.25 mm pilots and caps on your printer before installing electronics. The STL check confirms one closed oriented connected solid per printed part; it does not validate print strength or dimensional accuracy.

## Hardware and stack

- Four proposed **M1.6 × 12 mm countersunk screws**, length including head. Model head Ø3 mm and clearance Ø1.8 mm. Corner axes: (±34.3, ±24.8). Screw tips stop at front-Z=4.0, above a blind pilot floor at 3.8. Verify screw head/thread/pilot fit with an empty case; hand tighten. Do not substitute longer screws.
- PCB remains 66 × 48 × 1 mm, all 155 components on TOP toward the rear cover. Its centre moves from reference front-Z=4.7 to **4.2 mm**, giving front/rear surfaces 3.7/4.7. Existing Ø1.8 mm PCB holes and Ø3.2 mm support posts retain (±31.5, ±22). The upper posts are locally relieved for the actual microphone bodies. Case screws are separate from PCB supports.
- ER-TFT028A2-4 nominal body: 69.3 × 50.2 × 2.8 mm, front/rear Z=0.6/3.4. Window 58 × 43.6 mm, X=−2.65. **Only 0.30 mm nominal LCD-to-PCB clearance remains.** No flex bend or latch/tool envelope has been qualified.
- Battery remains an **unselected maximum envelope**, 52.5 × 35 × 5.7 mm, at X=−2, Y=5.0 (0.5 mm above the drawing datum to clear the real battery connector). Cell Z=9.3..15.0. A 45 × 28 × 0.20 mm soft insulating adhesive pad bonds it to the rear cover at Z=15.0..15.2. Use an appropriate removable pull-tab adhesive; no rigid pressure clamp or screw may bear on the pouch.
- **Keep Z=8.73..9.30 below the entire cell empty** for 0.57 mm expansion toward the PCB. This is a design allowance, not proof that an arbitrary cell is safe or fits. Never close the lid against resistance. Actual pack, protection, connector polarity, temperature and swelling specifications must be confirmed.
- Speaker allocation 38 × 9.5 × 4 mm at (−7.5,−19.8), Z=11..15. Coin motor Ø10 × 3.2 at (25,−18.5), Z=11.8..15. They require actual part selection and validated compliant mounting. No fabricated supplier CAD is substituted for either.

## Prototype assembly order

1. Deburr/support-clean the empty shells. Fit the lap, screws and moving caps without electronics. Inspect the narrow corner bosses and ledges for cracking.
2. Place the LCD into the front lip, keeping its active area aligned with the offset window. Confirm insulation and flex routing before retention; no LCD adhesive thickness is budgeted beyond the nominal stack.
3. Install privacy and power caps against the actual switch stems. Fit the TALK cap and its separate **0.10 mm spring interface, 2 × 5 mm**. It is a nonprinted spring-strip proposal, not a proven actuator. Round and insulate it; validate anchoring, electrical isolation, switch travel/force, rest gap and cap retention before energizing. Do not use the case if a control binds or bypasses the physical microphone disconnect.
4. Seat the PCB on front ledges, TOP components toward the battery/rear cover. Rear support posts contact its four mounting-hole lands; verify alignment by hand before closing. Do not force the PCB against the LCD.
5. Mount selected speaker/motor with a qualified thin compliant adhesive. Verify grille alignment and vibration coupling. Bond an approved cell to the rear cover using the soft insulating pad, keeping the pouch away from all fasteners.
6. Route insulated battery leads through the right-side channel (clear width 3.4 mm, X=25.2..28.6, Y=−10..14), with service slack to the battery header below the cell. Check the actual mated connector, bend radius, flex and wires by inspection. The model does not establish a minimum wire bend radius. Keep every lead clear of the seam and posts.
7. Lower the rear cover slowly, inspect the whole perimeter for trapped wires and confirm the cell reserve remains empty. Fit four screws by hand. Test TALK, privacy, power and USB plug insertion before powering the prototype.

## Checks and remaining work

The native assembly retains all 155 SHA-verified supplier meshes from 56 genuine JLCPCB imports. Nominal cell, expansion and transducer volume screening against actual supplier triangle surfaces passes. Closed shell STL surfaces also clear all supplier AABBs, PCB substrate and allocated volumes at a 0.001 mm contact tolerance; the cylindrical motor is checked as a cylinder. These checks do not prove manufacturing tolerances, containment, actuation or assembly access.

The TALK spring top is only **0.08 mm below the expanded cell envelope** before upper insulation; its nominal rest gap above the switch is about 0.04 mm. This is a critical tolerance issue. Do not treat the 16 mm design as production-ready until a measured prototype validates it; if it fails, the stack/linkage or enclosure depth must change.

Mic openings use the actual acoustic PCB-hole X coordinates (−27.23493 and +28.76507), with external ports at Y=26.75, Z=3.55. **Sealed acoustic ducts are still required** between these ports and the PCB holes through the narrow front gap. The status opening likewise needs a verified light guide. Antenna clearance/RF performance, LCD flex routing, cell/transducer selection, slider end travel/retention, screw purchase and drop/thermal/charging tests remain outstanding. MUSE service integration remains unverified.

PCB copper, component footprints, native PCB and the manufacturing ZIP are retained. Via drill ≥0.30 mm and pad ≥0.45 mm remain unchanged.