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WALKIE ONE    /    RAPID PRODUCT SOLUTIONS
WO 022 R9  |  04 September 2026  |  Prototype DFM and fit review     Page 1
Walkie One enclosure handoff
Concept 02.2 Silicone Monolith    |    Revision R9
Prepared for Rapid Product Solutions on behalf of Jacob Catalano. Please review and quote a thin, 
serviceable prototype enclosure using the supplied CAD and the material schedule in this document. The 
selected body measures 88 × 136 × 27.0 mm, with a continuous silicone front and sides over a rigid nylon 
chassis.
This package is ready for supplier DFM and prototype planning. Final fabrication depends on confirming the 
material grades, thin-wall process limits, button function and physical fit with the actual electronics. It is not a 
production tooling release.
The intended finish is warm ivory silicone, a terracotta PTT paddle and sage volume keys. The microphone 
opening is centered directly above the light, with 12 mm between centers. The play recess remains Ø33 mm 
at Y-43, with a curved 1.1 mm dish and larger triangle. It keeps an 8.5 mm bottom margin and 3.8 mm edge 
gap to the light. The rear-face service pad conceals a removable screw-fastened cover. Colors in CAD are 
visual targets; approve physical swatches before finishing.
Use the case-only STEP for nominal manufactured geometry. Use the native Fusion archive for 
assembly review, the part-level files for fabrication, BOM.csv for part identification, and the 
dimensioned reference PDF for inspection planning.

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WALKIE ONE    /    RAPID PRODUCT SOLUTIONS
WO 022 R9  |  04 September 2026  |  Prototype DFM and fit review     Page 2
Original concept reference
Concept 02.2 Silicone Monolith in the Lozenge form was the starting visual reference. Its soft ivory surface, 
terracotta side control, sage keys and recessed play area establish the intended character.
Original Concept 02.2 image from walkieone.com/concepts. This is concept imagery, not a photograph of the CAD or a 
dimensioned fabrication reference.
R9 reduces body depth from 28 to 27 mm while retaining the current 88 × 136 mm outline, Ø33 play dish, 
smaller acoustic field and microphone directly above the light. The centered rear wordmark and smaller 
Designed in Los Angeles inscription retain their approved sizes and spacing.
Use the current STEP geometry and the dimensions in this document for manufacture. Do not infer 
internal space, wall thickness or exact feature positions from the concept image.

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WALKIE ONE    /    RAPID PRODUCT SOLUTIONS
WO 022 R9  |  04 September 2026  |  Prototype DFM and fit review     Page 3
Slimmer body, same front design
Body depth is 1 mm (3.6%) smaller than R8. Each face moves inward 0.5 mm; front controls and supports 
follow the front face. The antenna support is integrated into the rear cover and the battery tray sits 0.2 mm 
lower. Width, height, corner radii and visible control layout are retained.
R9 detail rendered from the actual Fusion model. The microphone remains directly above the light. Surface colors 
indicate the intended finish.
Feature Previous R8 Current R9
Body depth / incl. LED 28.0 / 28.2 mm 27.0 / 27.2 mm
Width × height 88 × 136 mm 88 × 136 mm
Play dish / position Ø33 mm / X0 Y-43 Unchanged
Nylon faces / silicone skin 1.6 / 1.0 mm Unchanged
Battery front allowance 1.3 mm nominal 1.0 mm nominal
PCB-to-tray allowance 0.5 mm nominal 0.3 mm nominal
Antenna mounting Separate nylon seat Integral rear-cover landing
The light-to-play edge gap remains 3.8 mm and the bottom margin remains 8.5 mm. The dish has 0.8 mm 
nominal normal thickness; its raised symbol is 0.25 mm above the curved surface. The hidden plunger follows 
the dish underside. Set the mechanism against the actual switch and test silicone force, return and fatigue.

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WALKIE ONE    /    RAPID PRODUCT SOLUTIONS
WO 022 R9  |  04 September 2026  |  Prototype DFM and fit review     Page 4
Front and rear CAD views
  
Current R9 CAD, front at left and rear at right. The rear lettering is upright when viewed from the back.
Rear branding
Both markings are centered left to right on the removable silicone rear pad. The supporting copy retains its 
20% reduction introduced in R8. Designed in Los Angeles sits directly below the wordmark, with a 4.98 mm 
clear vertical gap. The supplied horizontal Walkie One wordmark is centered at the midpoint of the back, X0 
Y0. The logo retains its original split-weight letterforms and proportions.
Marking Placement and size
Walkie One wordmark X0, Y0 mm; 42 mm overall artwork width; 5.23 mm height
Designed in Los Angeles X0, Y-9 mm; 32 mm overall artwork width; 2.81 mm height; IBM Plex Sans 500
Recess and finish 0.15 mm molded deboss into the rear silicone pad; 0.85 mm nominal silicone remains 
locally. Carbon fill target #171716.
Use the supplied outlined SVG files for marking artwork. RPS should confirm fine-feature molding, a silicone-
compatible color-fill system, cure compatibility and rub adhesion before fabrication. Keep the service seam 
and screw recesses clear. The revised nominal body depth is 27 mm.

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WALKIE ONE    /    RAPID PRODUCT SOLUTIONS
WO 022 R9  |  04 September 2026  |  Prototype DFM and fit review     Page 5
Controls and rear surface
  
Left: PTT side. Right: the widened charging opening is centered beneath the volume keys. Its outer centerline is Z0; the 
connector remains on its original PCB axis.
Rear oblique CAD view shows the service-pad perimeter, shallow markings and rounded shell. Surface colors are visual 
targets for physical swatch matching.
The outer charging well is 17 mm high along Y and 20 mm across Z, with R3 corners. The inner 15 × 10 mm 
passage stays centered at Z-4.7396 to reach the unchanged board connector. A straight 14 × 9 mm rounded 
cable envelope with R2.5 corners clears the modeled case; test the actual cable and full seating on the 
prototype.

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WALKIE ONE    /    RAPID PRODUCT SOLUTIONS
WO 022 R9  |  04 September 2026  |  Prototype DFM and fit review     Page 6
Internal layout and assembly view
Internal CAD layout with the front tub and silicone skin hidden. Purchased hardware is included for fit review; flexible 
wiring still needs a physical routing check.
Exploded CAD visualization of the shell, rear pad and captured controls. Offsets are illustrative and do not prescribe a 
validated assembly path.

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WALKIE ONE    /    RAPID PRODUCT SOLUTIONS
WO 022 R9  |  04 September 2026  |  Prototype DFM and fit review     Page 7
Geometry and component fit
All CAD uses millimeters. X is left to right, Y is bottom to top and Z points toward the front. The origin is the 
center of the nominal outer body. No supplied component was scaled.
Feature Nominal dimension or position
Body and protrusions 88 W × 136 H × 27.0 D; up to 88.6 W at side keys; 27.2 D including the LED dome
Shell construction 1.6 mm front/rear wall + 1.0 mm silicone; 2.6 mm side wall; R19 plan corners and R5 exterior edge 
rounds
Front acoustic field 48 × 56 oval field centered X0, Y30; 453 through holes Ø1.30; X pitch 2.30 / Y pitch 2.00, 
staggered
Action and light Action X0, Y−43; Ø33 spherical dish, 1.1 deep, 0.8 membrane. Glyph 9.1 × 10.4, relief 0.25. LED 
hole Ø5.4 at X0, Y−20
Microphone aperture Ø1.8 at X0, Y−8; 12 mm directly above LED. Internal duct connects to the original mic board at 
X−24, Y−38.762
Side controls PTT centered Y10, 58 tall; volume keys Y30 and Y5, 19 tall; 0.3 perimeter allowance
USB access Right side at Y−32.1393. Outer well 17 Y × 20 Z, R3, centered Z0 with volume keys; inner 
passage 15 Y × 10 Z at Z−4.7396
Rear screws Four centers at X±34, Y−44 and +46; clearance Ø2.8, counterbore Ø5.3
Rear service opening 78 × 126 nominal silicone opening on rear face; peelable silicone surround permits cover removal
Basis for the thin body
The supplied populated PCB is 60 × 85.75 × 9.5 mm. Its placed depth is Z−9.3 to +0.2. The battery tray starts 
at Z0.5, leaving 0.3 mm above the board envelope. A 0.8 mm tray floor and 0.2 mm pad put the battery base 
at Z1.5. The supplied cell body is 60 × 36 × 7 mm; its protection feature reaches 8.4 mm above its base. This 
leaves 1.0 mm to the front cavity plane at Z10.9.
R9 retains the 1.6 mm nylon faces and 1.0 mm silicone skin. A 0.6 mm integral landing on the rear cover 
replaces the separate 1.0 mm antenna seat; antenna and PCB positions remain fixed. The front assembly 
moves rearward 0.5 mm and the battery tray drops 0.2 mm. The 1.0 mm battery allowance and 0.3 mm 
board-to-tray gap require physical tolerance, insulation and swelling checks before fabrication. This is a 
modest prototype reduction, not a proven minimum thickness.
The centered mic port uses a 2.4 × 1.0 mm internal channel, about 39.0 mm long, cut into the nylon front deck 
and capped by bonded silicone. The mic board retains X-24, Y-38 and moves rearward 0.5 mm with the front 
assembly. The 0.70 mm installed inlet gasket seals to Z11.23; the duct floor is 0.6 mm nominal. Verify sealing 
and speech-band response on the prototype.
The board is rigidly centered, rotated 180° about Z and translated to (0, −7, −4.55). The USB connector stays 
on the measured source axis. Its mating face is recessed about 14.2 mm from the outer right side. The outer 
well is centered Z0 beneath the buttons; the inner passage follows Z−4.7396. The clearance check uses a 14 
× 9 mm cable envelope with R2.5 rounded corners; test the actual overmold shape and full seating.

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WALKIE ONE    /    RAPID PRODUCT SOLUTIONS
WO 022 R9  |  04 September 2026  |  Prototype DFM and fit review     Page 8
Materials and fabrication
Please quote the following materials and identify the exact grade, supplier and process in the quotation. Any 
substitution requires an agreed sample or written change to this schedule. A printed TPU shell would be a fit 
surrogate and would not reproduce the specified silicone.
Parts Specified prototype material Process and finish
03, 04 and 11 Smooth-On Dragon Skin 30, platinum-cure 
silicone, 30 Shore A
Cast in finished tooling; ivory main skin and rear pad, 
terracotta PTT face, sage volume faces. RPS to confirm 
procurement and cure process.
01, 02, 07, 09, 
10, 12, 13, 15, 
16, 17
RPS Nylon PA from its SLS material schedule
SLS, depowdered; finish critical bores and sliding 
surfaces. RPS to name its current powder designation. No 
conductive coating.
08 speaker seal Rogers BISCO HT-800 medium silicone foam, 
0.79 mm stock
Cut annulus; 0.70 mm modeled installed thickness. 
Confirm compression on the actual speaker frame.
18 microphone 
seal
Rogers BISCO HT-800 medium silicone foam, 
0.79 mm stock
Cut annulus; 0.70 mm modeled installed thickness. Check 
airtight contact to the microphone port and nylon inlet seat.
Assembly 
supplies
Four stainless M2.5 × 8 screws; two 
nonconductive PET battery straps; 0.2 mm 
insulating pad
Screw heads ≤5.3 diameter, ≤2.4 high. RPS to select 
compatible adhesives/primers and verify retention without 
loading the battery pouch.
Process decisions for Rapid Products
The 453-hole silicone field, 0.8 mm action membrane and wraparound skin require a casting and demolding 
plan. Please propose the parting line, core strategy, venting, gating, shrink compensation and matte tool 
texture. Keep gates and flash off the front face and moving controls. The CAD describes finished parts, not 
mold tooling.
Bond the skin to the front chassis only where needed to hold alignment; preserve the ability to peel back the 
rear perimeter for service. Bond the rear pad to the removable rear cover. Do not bridge the service joint with 
adhesive. Keep all acoustic holes open and register the two perforated layers. Bond a continuous airtight seal 
around both edges and ends of the mic channel; prevent adhesive from entering the duct or its ports.
Suggested inspection targets are ±0.20 mm for rigid general dimensions, ±0.10 mm for finished critical fits and 
±0.30 mm for silicone general dimensions. These are proposed requirements, not verified RPS capabilities. 
RPS should return exceptions before committing to manufacture.
The rear pad includes molded debossed artwork with Carbon silicone-compatible fill. RPS must specify the fill 
material and verify adhesion on the cured silicone. The silicone grade is a concrete prototype choice. Long-
term wear, oils, UV exposure, tear resistance and button force need sample testing before selecting a 
production elastomer. The public RPS information confirms silicone work and SLS nylon, but does not confirm 
that it stocks Dragon Skin 30.

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WALKIE ONE    /    RAPID PRODUCT SOLUTIONS
WO 022 R9  |  04 September 2026  |  Prototype DFM and fit review     Page 9
Part schedule and file usage
Each row corresponds to one manufactured solid. Each part has a STEP and STL in assembly coordinates; 
identify the material by this schedule and BOM.csv. There are 21 fabricated parts; former part 19 is integrated 
into part 02. Purchased hardware and original source files are reference data.
Part identifier Qty Fabrication
01 front structural tub 1 SLS nylon
02 rear structural cover 1 SLS nylon
03 continuous silicone skin 1 Cast silicone
04 rear silicone service pad 1 Cast silicone
07 speaker edge cradle 1 SLS nylon
08 speaker front gasket 1 Cut silicone foam
09 battery tray 1 SLS nylon
10 ptt key 1 SLS nylon
11 ptt silicone face 1 Cast silicone
12 ptt switch cradle 1 SLS nylon
10 volume plus key 1 SLS nylon
11 volume plus silicone face 1 Cast silicone
12 volume plus switch cradle 1 SLS nylon
10 volume minus key 1 SLS nylon
11 volume minus silicone face 1 Cast silicone
12 volume minus switch cradle 1 SLS nylon
13 action plunger under membrane 1 SLS nylon
15 front switch holder 1 SLS nylon
16 rgb led support ring 1 SLS nylon
17 microphone cradle 1 SLS nylon
18 microphone acoustic gasket 1 Cut silicone foam
The case-only STEP excludes electronics. The Fusion file includes a separate purchased-hardware group, 
with the original board STEP and placed reference meshes. Do not fabricate anything prefixed REF or stored 
in source_inputs.
The native Fusion design contains editable direct BRep components. The included Python generator controls 
rebuild dimensions; this is not a sketch-driven Fusion feature timeline. STEP is the neutral geometry handoff. 
STL uses millimeters and is intended for the assigned process only.

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WALKIE ONE    /    RAPID PRODUCT SOLUTIONS
WO 022 R9  |  04 September 2026  |  Prototype DFM and fit review     Page 10
Prototype assembly
1. Print the rigid components first. Remove powder, deburr and trial-fit the shell. Finish screw holes and tap 
the 2.1 mm pilots to M2.5 × 0.45 as appropriate for the selected nylon. Confirm the proposed 8 mm screws 
engage without bottoming; do not force threads.
2. Insert the PCB from the rear into its locating rails. Verify bearing occurs on safe board edges and that 
connectors, exposed solder and components clear the rails. Add removable insulating retention after the 
physical fit check; the source does not supply a board fastening specification.
3. Fit the battery tray to its rail seats. Install a 0.2 mm insulating pad and two removable PET straps. Keep the 
pouch free of screw points and clamp loads. The 1.0 mm nominal front allowance is not a battery-maker-
approved swelling specification.
4. Install the three side switches in their adjustable cradles. Insert the captured rigid keys and attach their 
silicone faces. Set approximately 0.2 mm actuator freeplay and verify actuation and return before the 0.5 mm 
stop. Bond the cradles only after testing the actual switches.
5. Fit the front B3F4000 switch, hidden plunger and integral silicone action membrane. The nominal actuator 
gap is 0.2 mm, membrane gap 0.1 mm and inward hard-stop travel 0.55 mm. Check the real switch travel and 
elastomer force curve, then shim the carrier as necessary.
6. Seat the 40 mm speaker and its foam gasket. Its supplied mounting-ear span is 53.8 mm along X after a 
90° rotation; its center is Y43. Bond the cradle feet to the front deck while leaving the diaphragm and leads 
free. Keep the microphone in its side mount; fit the 0.79 mm stock foam inlet ring at 0.70 mm installed 
thickness. Seal the channel roof continuously before testing the new centered opening.
7. Attach the LTE flex antenna to the integral landing on part 02 using its factory adhesive. Taoglas specifies 
peel-and-stick mounting on non-metal surfaces; finish and test adhesion on the actual nylon landing. Part 19 
is no longer a separate component. Route battery and speaker leads and the antenna coax with strain relief. 
Confirm bend radii, connectors and solder clearances; avoid the button mechanisms, diaphragm, screws and 
seam.
8. Test USB charging, audio, microphone isolation and cellular reception before closing. Install the rear cover 
with four screws, then fit the silicone exterior and rear pad. Recheck button return and access with the final 
silicone and adhesive stack.
The wire shapes in the original STLs are straight reference leads. The placed packaging references 
retain the rigid battery, speaker, antenna and feed details, while those extended flexible leads are 
omitted. No cable routing, connector substitution or electronics redesign is implied.

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WALKIE ONE    /    RAPID PRODUCT SOLUTIONS
WO 022 R9  |  04 September 2026  |  Prototype DFM and fit review     Page 11
Validation and supplier review
The supplied ZIP contains one board STEP and seven component STLs. The side-switch STL represents one 
switch and is inserted three times. All eight originals are retained unchanged with SHA-256 checksums. The 
LED source includes non-watertight planar fragments; it remains reference geometry.
Check Recorded result
Manufactured solids 21 parts; all valid single BRep solids and watertight STL meshes
Fabricated-part intersections 0 overlaps above 0.005 mm³; see intersections.json
Hardware against case 0 conservative overlaps above 0.02 mm³; see hardware_clearance_screen.json
Hardware against hardware 0 conservative overlaps above 0.02 mm³; see hardware_pair_screen.json
Microphone channel Opening at Y-8 and inlet clear; old port closed; sampled duct, floor and roof verified
Play recess / guide Ø33 at Y-43; 1.1 mm dish, 0.8 mm membrane; rigid-guide travel screen in 
action_validation.json
Rear branding Wordmark at Y0; copy 32 mm wide at Y-9, 20% smaller; 0.15 mm deboss
Charging opening Outer well aligned Z0 with both volume keys; rounded 14 × 9 mm cable envelope 
clears case geometry
Fusion archive Exported, reopened and solid count verified in Autodesk Fusion
The hardware screens use the exact placed PCB STEP and convex hulls of connected nondegenerate source 
mesh pieces. They do not validate flexible leads, positive minimum clearances at every interface, assembly 
insertion paths, adhesive thickness or tolerance accumulation. Zero nominal overlap is only a geometry 
check.
Items to resolve with the physical prototype
 RPS acceptance of the 1.6 mm nylon face wall and 1.0 mm silicone skin, silicone molding strategy and 
the stated materials; sample-match colors and surface feel.
 Actual USB cable insertion, PCB edge retention, battery swelling/insulation requirements and complete 
cable routing.
 Switch actuation, return, freeplay, hard-stop travel and silicone membrane fatigue under part tolerances.
 Acoustic sealing, mic-channel leakage and speech-band response, microphone feedback isolation, 
speaker output, antenna performance and operating temperatures.
 Rear-skin service access, silicone bond strength, screw engagement and practical assembly sequence. 
No drop, ingress or life-cycle rating has been established.
Sources and design authority
Concept 02.2 establishes the visual direction. Enclosure dimensions are developed from the supplied 
component geometry and the assembly allowances recorded here. The website images are not dimensioned 
engineering drawings. Material information below is from the manufacturers and RPS.
Walkie One concept 02.2 — https://walkieone.com/concepts
Walkie One logo and type system — https://walkieone.com/design-system
RPS SLS process and materials — https://www.rapid-products.com/service/selective-laser-sintering-sls/
RPS silicone/casting capability — https://www.rapid-products.com/service/urethane-castings/
Dragon Skin 30 grade — https://www.smooth-on.com/products/dragon-skin-30/
Rogers HT-800 — https://www.rogerscorp.com/elastomeric-material-solutions/bisco-silicones/bisco-ht-800-medium-silicone-foam
Taoglas antenna adhesive mounting — https://www.taoglas.com/product/fxub63-ultra-wide-band-flex-antenna/
Sources checked 04 September 2026. No files sent or order placed.