PAGE 1
WALKIE ONE   /   CONCEPT 21.2   /   ASTRA R5
SUPPLIER REVIEW REPORT
Walkie One Concept 21.2 - Astra R5
Engineering handoff for Rapid Product Solutions. Concept 21.2 (Lozenge), Astra design, CAD revision
R5. This report supports engineering review, prototype fabrication and a quoted path to a manufacturable
product.
Current R5 assembly from validated CAD. Appearance colors are proposed; status lens shown illuminated.
28.8 mm finished thickness | 72 mm centered PTT | W perforated grille
Status: nominal CAD fit and motion checks completed. Electrical integration, complete wiring fit, physical qualification and
supplier manufacturing release remain open. This package is not an instruction to start tooling or ship production units.
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R5 CAD and handoff evidence

PAGE 2
WALKIE ONE   /   CONCEPT 21.2   /   ASTRA R5
SCOPE AND DECISIONS
Request to Rapid Product Solutions
Please review the current R5 enclosure and internal architecture, identify manufacturing changes, and
propose a phased build that preserves the exterior design. We need a physical fit article, a functional
engineering prototype, and an explicit route from that prototype to repeatable production.
Priority
Requested outcome
Preserve design
Soap-like rounded Lozenge form, warm cream grips, charcoal W grille, centered orange PTT, sage
volume keys and rear artwork.
Respect thickness
28.8 mm nominal including skins; 30.0 mm maximum finished product. Preserve this nominal
through process and tolerance planning.
Resolve integration
Verify the real populated PCB, missing cellular body, mating plugs, harness, firmware, charging
and RF interfaces.
Quote the work
Separate engineering, prototype parts, purchased items, electrical work, assembly, testing,
finishing and potential tooling.
Suggested first engagement. Review the STEP assembly and measured fit issues before committing to a
process. Return a marked-up change list, a material/process proposal, a test plan and a quotation with
assumptions. Do not resolve a fit issue by scaling the supplied electronics or silently changing the
appearance.
Ownership to agree. Walkie One approves appearance, behavior and the business requirements. Rapid is
asked to identify its fabrication, assembly and inspection scope and any subcontracted work. An identified
electrical/firmware owner must approve circuitry, programming and functional tests. The report does not
assume that Rapid already supplies those engineering services.
Supplier response. Identify fabrication, finishing and final assembly locations, responsible teams and
subcontracted work in the quotation. Confirm the processes and capabilities applicable to these parts. [W1,
W4]
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R5 release status and supplier scope; Rapid website [W1, W4], accessed 04 September 2026

PAGE 3
WALKIE ONE   /   CONCEPT 21.2   /   ASTRA R5
CONTENTS
Report navigation
04 Current design and fixed requirements
05 Concept 21.2 inspiration
06 Orientation atlas and coordinate system
07 Front geometry and visible features
08 Rear geometry and service access
09 Centered push to talk side
10 USB opening and local side web
11 Volume side and control reach
12 Top bottom and shallow angles
13 Front angle study
14 Rear angle study
15 Assembly architecture
16 Exploded side view and file authority
17 Rear cover removed
18 Internal section views
19 Front chassis features
20 Rear cover and clamp features
21 PTT mechanism and full travel
22 Volume and front action mechanisms
23 Battery speaker and support stack
24 Main PCB and missing cellular coverage
25 Microphone and status light
26 Antenna harness and connector access
27 W grille manufacturing definition
28 Centered rear wordmark and origin line
29 Color material and finish intent
30 Grip bonding and compliant interfaces
31 Fastener and insert system
32 Critical dimensions and tolerance planning
33 Assembly sequence for the first article
34 Complete assembly and service sequence
35 Electrical integration responsibilities
36 Firmware compatibility and required behavior
37 Completed nominal CAD validation
38 Priority issues for the engineering review
39 Physical acceptance and test records
40 Proposed manufacturing development route
41 Quotation scope and supplier response
42 Release control and sharing instructions
43 Custom parts schedule 1
44 Custom parts schedule 2
45 Custom parts schedule 3
46 Custom parts schedule 4
47 Purchased components and unresolved items
48 Complete fastener location schedule
49 Source index and evidence files
Each entry is a clickable page link. PDF bookmarks provide the same navigation. Measurements are millimetres unless a
different unit is stated.
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Walkie One Concept 21.2 | Astra CAD revision R5 | Document edition 2

PAGE 4
WALKIE ONE   /   CONCEPT 21.2   /   ASTRA R5
DESIGN DEFINITION
Current design and fixed requirements
Front view of the current assembly
Rear wordmark and centered supporting text
Requirement
Current design definition
Finished size
90.4 mm grip width x 28.8 mm depth x 152.4 mm height; 93.2 mm overall width including side
controls.
Push to talk
72 x 15 mm visible paddle; centered on the side at Y = 0, Z = 0; 0.6 mm nominal inward
travel.
Front identity
W logo formed by grille perforations; recessed charcoal metal plate.
Rear identity
Supplied WALKIE ONE wordmark above a much smaller Designed in Los Angeles line;
combined block centered at X = 0, Z = 0.
Internal hardware
Original PCB and supplied rigid component references maintained at scale 1.
Hand feel
Soap-like rounded ends: R29.2 outer profile; front perimeter R9.2 and rear R7.2. Fine-textured
elastomer skins.
This report defines the current product configuration and the engineering work needed to fabricate and qualify it. Numerical
dimensions and supplied STEP geometry govern; images explain orientation and appearance.
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Current CAD parameters; rear artwork definition; customer requirements

PAGE 5
WALKIE ONE   /   CONCEPT 21.2   /   ASTRA R5
DESIGN REFERENCE
Concept 21.2 inspiration
Visual reference for the Lozenge form, warm cream surfaces, charcoal grille, orange push-to-talk paddle and
sage volume controls.
Customer-supplied Concept 21.2 inspiration image.
Use this image for the intended form, color and surface character. The current CAD and specification pages define dimensions,
control positions, the W grille and rear branding.
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Customer-supplied Concept 21.2 Lozenge screenshot; received 04 September 2026

PAGE 6
WALKIE ONE   /   CONCEPT 21.2   /   ASTRA R5
EXTERIOR VIEWS
Orientation atlas and coordinate system
Front: look toward +Y
Rear: look toward -Y
PTT side: look toward +X
Volume side: look toward -X
Top: look toward -Z
Bottom: look toward +Z
Design coordinates. Origin at the body center. X points right when facing the front. Y points toward the
rear. Z points up. Front and rear viewing directions reverse the apparent left/right positions. Top and bottom
views are individually labeled, not arranged as a formal projection drawing.
The engineering views are CAD renderings; the inspiration page is the supplied visual reference. CAD images are not
photographs of a manufactured sample. Perspective-like views use parallel projection; display scale varies to make details
readable. Use dimension values and the STEP geometry rather than measuring a printed picture.
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R5 CAD and handoff evidence

PAGE 7
WALKIE ONE   /   CONCEPT 21.2   /   ASTRA R5
EXTERIOR VIEWS
Front geometry and visible features
90.4 mm grip width
152.4 mm
Feature
Nominal definition
Finished grip outline
90.4 wide x 152.4 high; rigid body 88.0 x 150.0
Grille
61.7 x 63.7 x 0.8; R15.85; center X = 0, Z = +34.5
Action key
34 visible diameter; center X = 0, Z = -32.0
Status opening
8.0 x 2.5 lens outline; center X = 0, Z = -6.2
Microphone passage
1.2 diameter; center X = +22.0, Z = -54.528
Inspect the front composition after applying the real texture and colors. Preserve the recessed grille and action-key glyph. The
microphone position uses the reconciled vendor board port; verify the physical board before committing the acoustic passage.
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astra_params.py; MECHANICAL_CORE_CHECKS.json; microphone reconciliation

PAGE 8
WALKIE ONE   /   CONCEPT 21.2   /   ASTRA R5
EXTERIOR VIEWS
Rear geometry and service access
Four accessible closure screws. Centers are X =
+/-34.0, Z = +/-61.5. Each closure uses an M2 x 12
socket cap screw into a chassis insert.
Serviceable seam. The split plane is Y = +4.2. Each
grip belongs to its own case half. Bonding must not
bridge the seam or obstruct the four screw recesses.
Rear identity. The supplied WALKIE ONE wordmark
sits above the much smaller “Designed in Los
Angeles” line. The combined block is centered at X =
0, Z = 0, with 0.25 mm deboss.
Finish approval. Inspect the wordmark and small
text for legibility, surface grain, color and edge
condition on a physical sample.
Rear left upper view
Rear right upper view
Rear artwork is defined from the rear viewing direction. Do not mirror the text when preparing a mold insert, fixture or marking
program. The marking sits on the center of the rear face, clear of the service screw recesses. Rear orthographic shading
enhances the shallow relief for visibility.
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R5 CAD and handoff evidence

PAGE 9
WALKIE ONE   /   CONCEPT 21.2   /   ASTRA R5
EXTERIOR VIEWS
Centered push to talk side
28.8 mm
72 mm visible paddle
Feature
R5 nominal
Visible paddle
72.0 long x 15.0 wide; center Y = 0, Z = 0
Equal envelope margins
40.2 above/below; 6.9 toward front/rear
Projection and travel
1.6 proud of side grip; 0.6 inward stop travel
Opening clearance
0.30 per side; finished paint/texture must not consume the sliding gap
USB adjacent web
1.226 minimum separation of projected aperture profiles
The 1.226 mm web value is an in-plane width, not the wall thickness. It is a local inspection priority. Test the lower end of the
PTT with representative USB plug overmolds installed. The original PCB model does not contain a mated cable plug.
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CENTERED_PTT_SWEEP.json; PTT_USB_WEB.json; nominal travel report

PAGE 10
WALKIE ONE   /   CONCEPT 21.2   /   ASTRA R5
EXTERIOR VIEWS
USB opening and local side web
Enlarged PTT-side view around the USB opening and lower end of the centered paddle.
Feature
Nominal geometry or review finding
USB pocket
7.5 in Y x 13.5 in Z, 2.0 corner radius
Pocket center
Y +5.7755, Z -43.5145
Minimum projected opening gap
1.226
What the gap means
Nearest separation of aperture profiles on the side datum; not through-wall
thickness
Component coverage
Board-side connector is modeled; mated plug overmold and cable are absent
The lower end of the centered paddle is adjacent to this USB opening. Inspect the local web for bending,
damage after button presses, and process defects. Check that the chosen USB cable can fully seat while the
lower end of the PTT remains usable. Record plugged and unplugged force/return results.
A clearance failure with the selected cable should trigger a documented local design review. Preserve the 28.8 mm target,
centered paddle and original connector placement unless a new revision is approved. No connector-load or cable-fit result is
claimed by the current CAD pass.
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PTT_USB_WEB.json; USB pocket geometry from current R5 parameters

PAGE 11
WALKIE ONE   /   CONCEPT 21.2   /   ASTRA R5
EXTERIOR VIEWS
Volume side and control reach
Upper key. Volume plus is centered at Z = +18.0. The plus
glyph provides visual and tactile differentiation.
Lower key. Volume minus is centered at Z = -8.0. Center
spacing is 26.0 mm; the two visible 20 mm-long capsules leave
6.0 mm between their straight envelope ends.
Depth position. Both visible keys remain at Y = -1.2, a small
forward offset. Each visible capsule is 20.0 x 14.0 mm and
projects 1.2 mm beyond the side grip.
Interaction to qualify. Test single presses, long presses,
repeat behavior and accidental activation with both hands and
representative hand sizes. Physical volume-key firmware is not
yet implemented in the reviewed source.
Inside view of the two separate caps, pads, switches and mechanical FR4 carrier.
The visible dimensions differ from each complete cap bounding box because the cap includes a hidden flange and stop tab.
Keep the user-facing geometry and the functional internal geometry associated with the same R5 part.
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R5 CAD and handoff evidence

PAGE 12
WALKIE ONE   /   CONCEPT 21.2   /   ASTRA R5
EXTERIOR VIEWS
Top bottom and shallow angles
Top orthographic view
Bottom orthographic view
Upper front oblique view
Lower front oblique view
Envelope
Nominal mm
Grip depth
28.8
Rigid body depth
26.4
Each grip skin
1.2
Overall width including side caps
93.2
The nominal flat bottom contact patch reported by the model is 32.0 x 12.4 mm. Its presence does not establish free-standing
stability. Test the actual mass distribution, surface friction and cable loads before making a standing-use claim.
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R5 CAD and handoff evidence

PAGE 13
WALKIE ONE   /   CONCEPT 21.2   /   ASTRA R5
EXTERIOR VIEWS
Front angle study
Front left from above
Front right from above
Front left from below
Front right from below
Use these views to review the continuous lozenge contour, the grille recess, PTT projection, volume key relationship and front
action button. Proposed finishes should retain the same silhouette after finishing and assembly. Rendered highlights and
shading do not specify texture depth or gloss.
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R5 CAD and handoff evidence

PAGE 14
WALKIE ONE   /   CONCEPT 21.2   /   ASTRA R5
EXTERIOR VIEWS
Rear angle study
Rear left from above
Rear right from above
Rear left from below
Rear right from below
The service fasteners remain visible from the rear and the grip split follows the structural seam. Review the transition into the
side openings, local grip edge thickness and the accessibility of the screw heads with the intended driver. No belt clip, lanyard
mount or docking feature is specified in this revision.
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R5 CAD and handoff evidence

PAGE 15
WALKIE ONE   /   CONCEPT 21.2   /   ASTRA R5
INTERNAL CONSTRUCTION
Assembly architecture
R5 presentation exploded view. Offsets separate layers for inspection; they are not validated removal paths.
Layer or group
Role
Front grip and metal grille
Appearance, grip surface and perforated speaker cover
Front structural chassis
Control guides, insert bosses, board supports and internal component retention
Internal hardware
Original PCB, speaker, battery, switches, microphone, indicator and antenna
Rear service cover and grip
Rear PCB/pouch pads, antenna support, closure and requested marking
The mechanical assembly contains 40 custom solids and 28 fastener occurrences. The full assembly contains 429 solids after
the installed component references and the original 306-solid PCB are included. Solid count is a CAD topology count, not a
procurement quantity.
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R5 CAD and handoff evidence

PAGE 16
WALKIE ONE   /   CONCEPT 21.2   /   ASTRA R5
INTERNAL CONSTRUCTION
Exploded side view and file authority
Exploded PTT-side projection makes the face-to-face layer separation visible.
Geometry authority. Use the R5 per-part STEP files for fabrication discussions. Use the full assembly to
understand placement and component context. The mechanical assembly provides the custom parts and
fasteners without the original electronics assembly. STL and 3MF files are convenience mesh exports; their
coordinates are assembled positions.
Presentation offsets. Front grip, grille, rear cover, rear grip, caps and selected hardware have
documented offsets in the exploded model. Those offsets were chosen to make the assembly readable.
Check real insertion directions, access to tools and service-loop lengths with physical parts.
Do not manufacture diagnostic references. The supplied reference inputs include component meshes
and an explicitly assumed modem keepout. Those are engineering reference inputs. The product assembly
excludes the diagnostic PCB boxes, the unconfirmed modem keepout and unassigned wire-route proposals.
Complete assembly and part filenames are indexed near the end of this report. The current CAD archive, artwork and validation
records are included in the sharing package.
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R5 CAD and handoff evidence

PAGE 17
WALKIE ONE   /   CONCEPT 21.2   /   ASTRA R5
INTERNAL CONSTRUCTION
Rear cover removed
Oblique service view with rear cover, its pads and antenna
group hidden.
Rear orthographic view of the remaining assembly.
The board occupies the lower portion of the enclosure and the battery sits above it. The board is captured
by edge supports and cover pads; the original PCB has not been drilled, trimmed or resized. The battery is
supported by a separate tray rather than by the speaker magnet.
The display hides the complete rear subassembly to expose the packing. In a real service operation the
antenna and harness may still connect the halves. A safe opening distance and service-loop arrangement
must be established before the cover is pulled away.
Service check
Required evidence
Board seating
Contacts only at designed supports; no component or solder-joint preload
Cover closure
Full seating without forced compression or trapped wires
Removal
Battery disconnect and PCB access demonstrated without prying on sensitive hardware
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R5 CAD and handoff evidence

PAGE 18
WALKIE ONE   /   CONCEPT 21.2   /   ASTRA R5
INTERNAL CONSTRUCTION
Internal section views
Display cut at X = 0, viewed from the right/front.
Display cut at X = -34.5, viewed from the PTT side.
These clipped views expose relationships between the front controls, speaker, battery support and original
PCB. They are display cutaways, without drafting hatching or a certified wall-thickness analysis. The clipping
operation changes only visibility, not the supplied manufacturing geometry.
The internal layout uses the supplied rigid components at their original sizes. Nominal structural wall is 2.0 mm, with the
documented local J3 relief exception. The LED optical gap is 0.4 mm. Original PCB clearance remains nominal and excludes
unmodeled mating plugs and wiring.
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R5 CAD and handoff evidence

PAGE 19
WALKIE ONE   /   CONCEPT 21.2   /   ASTRA R5
INTERNAL CONSTRUCTION
Front chassis features
Inside oblique view of the PA12 chassis
Inside rear-facing view
Integrated supports. The chassis combines closure and carrier bosses, control stop ribs, board ledges and
stops, the battery tray, speaker hooks, microphone seats and the indicator cup. The additive prototype
route allows these features to be reviewed together before a tooling architecture is chosen.
Manufacturing review. Inspect the roots of thin ribs, blind insert floors, local support bridges and the long
PTT opening. Decide build orientation and post-processing so support faces and guide surfaces remain
usable. Remove powder or debris from every cavity and blind feature; do not leave finishing buildup in cap
guides.
Tooling development. Transverse openings, retaining hooks and internal geometry require draft, parting-line, undercut and
tool-access review. No mold-flow result, draft analysis or tooling design is supplied. Proposed tooling changes must return as a
new revision for approval and fit checks.
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R5 CAD and handoff evidence

PAGE 20
WALKIE ONE   /   CONCEPT 21.2   /   ASTRA R5
INTERNAL CONSTRUCTION
Rear cover and clamp features
Inside oblique view of the rear cover
Inside front-facing view
The rear cover carries the PCB clamp pads, distributed battery foam posts and antenna landing/retention
features. Cover pads complete the retention system only when their material, compressed height and
assembly loads are qualified. The cover must seat before tightening torque is used.
Local feature
Nominal or review requirement
J3 relief
Inner pocket around the tall connector; sampled local wall approximately 1.47 mm
PCB clamp pads
1.0 nominal free thickness modeled at 0.8 compressed
Battery lid pads
3.0 nominal free thickness modeled at 2.5 compressed
Antenna backing
0.2 nominal adhesive bondline
Closure
Four M2 x 12 screws into thermoplastic chassis inserts
The 1.47 mm value is a sampled local corner measurement on the supplied cover geometry, not a minimum-wall certification of
the entire enclosure. Inspect the actual J3 relief and surrounding cover stiffness.
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R5 CAD and handoff evidence

PAGE 21
WALKIE ONE   /   CONCEPT 21.2   /   ASTRA R5
CONTROL ENGINEERING
PTT mechanism and full travel
Isolated PTT assembly viewed from inside
Internal flange, actuator pads and switch layout
Parameter
Nominal / evidence
Visible center
Y = 0, Z = 0
Internal switch centers
Z = -23.0 and +31.0
Hidden retention datum
Z = +4.0; intentionally offset from the visible paddle
Actuator pads
Two silicone pads, 2.3 mm axial thickness, 5.0 mm diameter
Stop movement
0.6 mm inward; dedicated stop gap 0.6 at rest and 0.0 at full stroke
Continuous sweep
No unintended rigid overlap through the modeled 0.6 mm translation
The sweep excludes the silicone pads because their compression is intentional. It does not simulate tilt, elastic bending, switch
force or tolerances. Press the upper end, center and lower end of the 72 mm paddle; record actuation and return at the
tolerance limits. Verify the two switch contacts and parallel wiring electrically.
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CENTERED_PTT_SWEEP.json; MECHANICAL_CORE_CHECKS.json control travel

PAGE 22
WALKIE ONE   /   CONCEPT 21.2   /   ASTRA R5
CONTROL ENGINEERING
Volume and front action mechanisms
Volume keys, pads, side switches and carrier
Action key, pad, front switch and carrier
Each volume key has an individual pad, switch and stop tab. The round action cap has an anti-rotation
feature and stop posts that bear against its carrier. The mechanical carrier patterns include mounting
provisions; they do not supply copper routing, plated holes or a finished electrical daughterboard.
Control
Pad thickness
Nominal stroke
Compliance budget at stop
PTT / volume
2.3 mm
0.6 mm
0.15 to 0.45 mm pad compression
Front action
1.5 mm
0.6 mm
0.10 to 0.40 mm pad compression
These compression budgets follow the reviewed switch pretravel bands. Pretravel is not permissible
overtravel. Supplier trials must establish pad grade, durometer, compression set and actual switch loading.
Apply finish to cosmetic surfaces while protecting the sliding and stop interfaces.
Physical volume inputs still need firmware implementation. The front action behavior, long-press behavior and feedback must
be agreed before an end-to-end sample can pass.
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R5 CAD and handoff evidence

PAGE 23
WALKIE ONE   /   CONCEPT 21.2   /   ASTRA R5
COMPONENT INTEGRATION
Battery speaker and support stack
Battery, speaker and compliant interfaces isolated
Central display cut exposing the integral support tray
Interface
Design intent
Speaker rim to chassis
Foam ring OD 40 / ID 36; 1.3 free thickness shown at 1.0 compressed
Speaker to tray
0.5 nominal gap between magnet and integral tray
Battery tray
1.0 structural tray, with 0.8 foam shown at 0.5 compressed
Battery body
Source reference approximately 60 x 36 x 7; rigid body and tab retained at scale 1
Pouch retention
Distributed cover foam; no qualified swelling allowance or clamp force yet
Keep the speaker diaphragm unloaded and the pouch clear of sharp edges, screw tips and hard pressure. Validate the actual
cell dimensions, tab/lead geometry, protection, charging conditions and thermal behavior. Foam displacement cannot be
treated as a verified battery swelling specification.
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R5 CAD and handoff evidence

PAGE 24
WALKIE ONE   /   CONCEPT 21.2   /   ASTRA R5
COMPONENT INTEGRATION
Main PCB and missing cellular coverage
Original board viewed from the front of the enclosure
Original board viewed from the rear of the enclosure
Preserved source. All 306 solids from the supplied STEP remain at scale 1. The installed bounds are
approximately X -41.294 to +18.700, Y +1.215 to +10.715 and Z -61.250 to +24.500. Connector models
establish geometry only; their pin counts and shapes do not identify their electrical functions.
Missing information. The requested SIM7670G body is absent from the source assembly. No additional
populated-board drawing or photograph is available. A separate 24 x 24 x 2.4 mm assumed keepout is
provided for discussion and is excluded from the product assembly. Its placement is unconfirmed.
Incoming reconciliation. Obtain the actual board for inspection, record hardware revision and photograph both faces.
Compare every tall component, shield, connector, antenna feed and cable exit. Resolve missing coverage before a final
enclosure or harness release. A pass against the supplied STEP cannot establish the fit of components that it omits.
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PCB_PLACEMENT.json; pcb_product_names.json; separate unconfirmed keepout

PAGE 25
WALKIE ONE   /   CONCEPT 21.2   /   ASTRA R5
COMPONENT INTEGRATION
Microphone and status light
Microphone board, acoustic gasket and clamp arrangement
LED reference, carrier and clear status lens
Microphone alignment. The intended front port is at X +22.0, Z -54.528. The supplied simplified STL
marker differs from the vendor board port by approximately 0.71 mm. The design uses the vendor-derived
port location; verify the actual board revision and orientation before finalizing the 1.2 mm front passage and
foam duct.
Optical alignment. The named RGB lamp and the clear diffusing lens have a 0.4 mm nominal gap. The
source LED mesh is partial/non-watertight; a conservative body envelope was used in the mechanical
checks. Validate real package height, lead orientation, current limiting, light leakage and diffusion.
Interface
Nominal / intended
Microphone duct
Foam OD 6 / ID 1.5; 2.3 free thickness shown at 1.9
Lens material
Clear diffusing polymer; amber in images is an illuminated state
LED electrical orientation
Manufacturer drawing lists common cathode; confirm actual pins and circuit before
wiring
No sealed or ingress-protected acoustic performance is claimed. Acoustic mesh, adhesive compatibility and any ingress
requirement need an agreed specification.
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R5 CAD and handoff evidence

PAGE 26
WALKIE ONE   /   CONCEPT 21.2   /   ASTRA R5
COMPONENT INTEGRATION
Antenna harness and connector access
Isolated LTE flex antenna reference
Antenna positioned on the inside of the rear cover
The flex is placed on its rear-cover landing with the feed facing inward and a nominal 0.2 mm adhesive
backing. The supplied reference includes a 150 mm coax lead budget. Neither RF port is assigned from
connector appearance; identify the approved LTE feed electrically.
Develop an approved harness for the supplied internal layout. The supplied PCB omits mating plugs, wire
bend envelopes and service loops. Do not infer a complete cable fit from the rigid-component clearance
report.
Harness drawing must define
Inspection must demonstrate
Connector part, pin number, signal and polarity
Correct keying, continuity and electrical interface
Wire gauge, insulation, route and bend limits
No pinching, sharp-edge contact or forced bends
Strain relief and service-loop length
Cover opening and repair without connector overload
RF cable routing and antenna restrictions
Installed RF performance with battery, grille and normal hand
grips
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R5 CAD and handoff evidence

PAGE 27
WALKIE ONE   /   CONCEPT 21.2   /   ASTRA R5
APPEARANCE AND FABRICATION
W grille manufacturing definition
Actual 721-hole grille geometry. The W is formed by the perforation pattern, not a printed overlay.
Feature
Nominal
Plate and pocket
61.7 x 63.7 x 0.8 plate in 62 x 64 pocket
Corner and fit
15.85 plate corner radius; 0.15 clearance per side
Lattice pitch
2.0
Hole diameters
Base 0.90; W classes 1.10, 1.25 and 1.40; halo class is solid plate
Minimum hole ligament
0.60 nominal between adjacent largest holes
Open area and recess
16.93% open area; 0.30 below the grip surface
The acoustic baffle behind the grille has a 38.5 mm diameter opening. Perforations outside it are blind against the chassis. Use
the supplied DXF to retain the brand pattern, and propose a cutting/etching process that controls burrs, flatness, finish buildup
and small ligaments. Qualify intelligibility, buzz and output with the actual finished grille.
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R5 CAD and handoff evidence

PAGE 28
WALKIE ONE   /   CONCEPT 21.2   /   ASTRA R5
APPEARANCE AND FABRICATION
Centered rear wordmark and origin line
Current CAD deboss detail. Relief shading makes the engraving visible; no paint fill is specified.
Artwork field
Definition
Primary mark
WALKIE ONE; approved split-weight wordmark artwork
Supporting line
Designed in Los Angeles
Type source
Supplied Inter-based wordmark outlines; IBM Plex Sans Regular 400 for the supporting
line
Nominal size
Wordmark 48.0 wide x 6.187 high; supporting line 26.753 wide x 2.380 high, 2.5 mm font
size
Center and spacing
Combined block centered at X = 0, Z = 0; 3.0 clear vertical gap between lines
Placement and depth
Line centers Z +2.690 and -4.593; 0.25 deboss into rear skin
Residual skin
0.85 nominal between deboss floor and rear adhesive interface
The approved wordmark was converted from its supplied SVG and embedded font into vector outlines,
preserving its split weights and spacing. The CAD uniformly scales and centers the artwork. Do not
substitute a typed logo, stretch the artwork, or mirror the rear-view registration.
Approve a physical textured sample for the small supporting text, recess edge quality and legibility. The supporting line
identifies the design location. Manufacturing and assembly locations should be stated separately in the supplier quotation.
Engineering review and prototype quotation   |   04 September 2026
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Walkie One design system [W6]; supplied wordmark SVG and font provenance; current rear CAD

PAGE 29
WALKIE ONE   /   CONCEPT 21.2   /   ASTRA R5
APPEARANCE AND FABRICATION
Color material and finish intent
Warm cream shell, charcoal grille and orange PTT
Sage volume controls and warm cream action cap
Part family
Proposed route / approval required
Chassis and cover
PA12 additive fit prototype; process, orientation and compensation to supplier review
Grip skins
Separate 1.2 mm flexible warm cream skins; fine-pebbled elastomer; 55 Shore A starting
swatch, grade and hardness by test
Control caps
Rigid polymer with orange, sage and cream appearance; preserve guide surfaces
Grille
0.8 mm metal, dark charcoal; exact alloy and coating to approve
Lens
Clear diffusing optical polymer
Finish standard
Physical color, grain, sheen and wear samples; no Pantone, gloss or texture grade
released
Render colors communicate the palette only. Specify a low-gloss, fine-pebbled elastomer skin; start physical trials at 55 Shore
A, comparing 45-60 A. Texture is a finish specification, not modeled relief. Approve dry and damp grip, lint pickup, cleaning,
wear and bond tests on physical samples. Hardness and chemistry remain supplier selections. See the grip trial plan and
process reference in docs/MATERIALS_AND_PROCESS.md.
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R5 CAD and handoff evidence

PAGE 30
WALKIE ONE   /   CONCEPT 21.2   /   ASTRA R5
APPEARANCE AND FABRICATION
Grip bonding and compliant interfaces
Separate front grip skin
Separate rear grip skin
Modeled grille and grip adhesive
interfaces
The adhesive shapes reserve nominal bondlines. They are not adhesive material selections or proof of bond
strength. The grille uses a perimeter bond, the rear grip has a panel interface, and the front grip has
discrete side patches. The lower-left patch occupies Z -44 to -38, with clearance from the PTT opening.
Interface
Nominal geometry
Qualification
Grille / grip PSA
0.10 thick; grille rim bond width 1.2
Adhesive, primer, peel and thermal aging
Antenna backing
0.20 thick
RF-safe attachment and flex retention
PCB clamp pads
1.0 to 0.8 compressed
Board stress, recovery and creep
Battery tray foam
0.8 to 0.5 compressed
Pouch load and thermal suitability
Battery lid pads
3.0 to 2.5 compressed
Cell variation, retention and swelling review
Keep adhesive out of cap guides, screw recesses and acoustic passages. Demonstrate peel resistance and serviceability after
aging, cleaning, sweat/skin contact and repeated handling using an agreed test profile.
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R5 CAD and handoff evidence

PAGE 31
WALKIE ONE   /   CONCEPT 21.2   /   ASTRA R5
MANUFACTURING REVIEW
Fastener and insert system
Upper left carrier region showing the boss, insert and screw context.
Item
Quantity
Nominal role
ruthex RX-M2x4
14
Chassis inserts
M2 x 12 socket cap screw
4
Rear closure
M2 x 6 socket cap screw
10
Switch and LED carriers, microphone bracket
Insert pilot / boss
3.2 / 6.4
diameter
Process tuning required
Blind depth
5.0 side
carriers; 6.0
elsewhere
Inspect residual floor and local wall
The listed insert is a thermoplastic heat-set candidate with official reference geometry. A cast thermoset
route needs separately engineered molded or bonded retention. Determine insertion settings and
tightening torque through material-specific trials; no torque value is released in this report.
The four side-carrier pilots extend 1.0 mm into the nominal front wall zone, leaving approximately 1.0 mm to the outside
surface on that local axis. Microphone bracket bores enter that zone by 0.5 mm. Negative “bore bottom to inner wall” values in
the schedule describe this geometry, not a negative remaining wall. Inspect the real floors and root strength.
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R5 CAD and handoff evidence

PAGE 32
WALKIE ONE   /   CONCEPT 21.2   /   ASTRA R5
MANUFACTURING REVIEW
Critical dimensions and tolerance planning
Characteristic
Design nominal
Required supplier action
Finished thickness
28.8; customer maximum
30.0
Allocate warpage, skins, bondlines, finishing and closure
variation
Cap perimeter gap
0.30 each side
Keep return clearance at process and finish extremes
Cap stop movement
0.60
Check actuation, pad compression and switch protection
Grille perimeter gap
0.15 each side
Control plate flatness, cut size, coating and pocket size
PCB edge locating gap
0.30
Fit actual board outline and assembled height variation
J3 local wall sample
1.47 approximately
Inspect wall quality and corner stiffness
PTT to USB web
1.226 in-plane minimum
Inspect web and plugged-cable operation
LED optical gap
0.40
Inspect actual lamp/lens tolerances and output
Nominals are not tolerances. The supplied STEP provides geometry; it does not establish supplier
capability or a signed acceptance drawing. Agree datums, process-specific tolerances, inspection methods
and cosmetic limits before fabricating an interchangeable mating set.
Fit budget method. For a sliding cap, start with the nominal 0.30 mm one-sided clearance and subtract
the closing effects of opening error, cap error, finish thickness and deformation. Establish a positive
accepted running clearance from a tested sample. Do not assign independent tolerances that consume the
same clearance twice.
Review end-press tilt and the long paddle as well as pure axial movement. No general mass, center-of-gravity, waterproofing,
drop rating or thermal limit is released by the CAD measurements.
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R5 CAD and handoff evidence

PAGE 33
WALKIE ONE   /   CONCEPT 21.2   /   ASTRA R5
ASSEMBLY AND SERVICE
Assembly sequence for the first article
1. Clean chassis and inspect all supports
2. Fit caps, pads, carriers and indicator
1 Inspect before finishing. Compare incoming rigid hardware with the reference files. Deburr every
cable-facing and pouch-facing edge. Confirm the PTT/USB web, local J3 relief, cap openings, board ledges
and blind-hole floors. Record deviations before further work.
2 Install inserts. Use an appropriate supported fixture and the agreed thermoplastic installation process.
Keep axes aligned and inspect boss roots and hole floors. Perform retention/torque trials before accepting
the full set.
3 Fit controls. Insert retained caps from inside, install actuator pads and carriers, and set the rest gaps.
Demonstrate full return and retained movement before closing the enclosure. Verify end and center PTT
actuation. Electrical wiring follows an approved diagram, not the mechanical part placement.
4 Fit optical parts. Seat the clear lens and LED carrier. Verify actual LED pin orientation, optical gap, lead insulation and an
approved current-limiting circuit. Check the intended status colors.
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R5 CAD and handoff evidence

PAGE 34
WALKIE ONE   /   CONCEPT 21.2   /   ASTRA R5
ASSEMBLY AND SERVICE
Complete assembly and service sequence
3. Install speaker, microphone and acoustic interfaces
4. Seat PCB and battery before rear closure
5 Speaker and microphone. Place the speaker rim gasket and engage its retaining hooks without loading
the diaphragm. Align the real microphone port and install its gasket, foam strips and bracket. Inspect each
acoustic path for blockage or leaks.
6 Board and battery. Seat the original board on its ledges and stops. Place the pouch on the tray foam
with its tab zone clear. Verify no hard compression, screw contact or trapped lead. Actual missing
component coverage must be reconciled before closure.
7 Rear subassembly and harness. Attach the antenna, route the approved harness, and fit PCB/pouch
pads. Demonstrate connector engagement, bend allowance and service slack. Close the cover with the four
M2 x 12 screws only after it seats freely.
8 Finish and service check. Bond final skins and grille after fit/functional acceptance. Keep the seam and closure screws
accessible. For service, support the cover, disconnect the battery and required interconnects, then reverse the sequence
without prying against the pouch, diaphragm or RF connectors. Replace damaged compliant parts and contaminated adhesive.
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R5 CAD and handoff evidence

PAGE 35
WALKIE ONE   /   CONCEPT 21.2   /   ASTRA R5
ELECTRICAL AND FIRMWARE
Electrical integration responsibilities
Function
Current evidence
Work before connection or release
Processor and radio
ESP32 and modem-related model
names
Confirm actual board BOM, schematic, power rails and
interfaces
Battery and charger
Battery reference; BQ24074 model
label
Verify polarity, charging settings, protection and thermal
behavior
Speaker output
Speaker and amplifier model
references
Confirm amplifier output, power/gain and load
compatibility
Microphone
I2S breakout reference
Confirm supply, BCLK, WS, data, select and sample format
Controls
Two PTT, two volume, one action
switch
Verify common terminals, wiring, pullups, debounce and
input mapping
Indicator
RGB reference lamp
Confirm pin order, drive circuit and current limits
Antenna / USB
Connector geometry only
Identify actual RF feed and USB power/data functions
The two five-pin headers J3/J9, three-pin J11, four-pin J8 and two-pin J1/J2/J10/J12 are not assigned functions
by pin count. J5 and J6 are RF connector geometry; neither is identified as LTE from appearance. Keep
harness endpoints unassigned until the electrical owner confirms the nets.
The four 1.6 mm FR4 carriers are mechanical patterns. Approve copper, plated holes, solder retention,
connectors and hand-wire fixation, or generate production daughterboards. No approved Gerbers, netlist,
connector schedule or complete harness drawing is supplied.
Bring up the verified board separately before installing it in the enclosure, then continuity-check the harness and repeat
functional and thermal checks after integration. This is a proposed validation order, not evidence that a powered test has
occurred.
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R5 CAD and handoff evidence

PAGE 36
WALKIE ONE   /   CONCEPT 21.2   /   ASTRA R5
ELECTRICAL AND FIRMWARE
Firmware compatibility and required
behavior
Reviewed software assignment
GPIO / state
Required integration
Listen / action
1
Confirm front-key role and board connection
Speak / PTT
2; recording while LOW
Confirm wiring, debounce and release behavior
Existing power input
42
Agree power, sleep and wake behavior
Microphone BCLK / WS / data
7 / 8 / 9
Verify connector mapping and audio format
Amplifier BCLK / WS / data
10 / 11 / 12
Verify amplifier and enable circuit
Amplifier enable
41
Confirm polarity
RGB red / green / blue
21 / 39 / 40
Verify circuit and LED orientation
Physical volume keys
Not implemented
Assign approved inputs and add handlers
These are assignments from the reviewed firmware source, not an approved wiring table for the supplied
STEP board. The source review was recorded at commit e408cd0e9552587bbac2909959b84a7f39a0d65e.
No firmware was changed, built, flashed or provisioned during the mechanical work.
Memory gate. The PCB CAD names an N8R2 module. The reviewed source assumes 16 MB flash and 8 MB
OPI PSRAM and reserves a 6 MiB playback buffer. Confirm the real module suffix and reconcile the build
configuration before bring-up. The CAD library name alone is not proof of the populated variant.
The existing software changes volume from 0 to 10 with serial + and - commands; physical volume-key handlers remain to be
implemented. Supply a versioned binary, hardware compatibility record, provisioning procedure and serial-number test log
before functional shipment.
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FIRMWARE_AND_LED_INTEGRATION.md; firmware_source_provenance.json; recorded read-only source review

PAGE 37
WALKIE ONE   /   CONCEPT 21.2   /   ASTRA R5
EVIDENCE AND QUALIFICATION
Completed nominal CAD validation
Check
Completed result
What it establishes
Custom part validity
40 valid single solids
Nominal custom solid topology
STL and 3MF
40 watertight STL; mm 3MF
Closed mesh exports and recorded units
Independent STEP import
43 files valid
40 part files plus 3 assembly files reopen
independently
Custom / fastener contacts
207 nearby pairs; no unintended
overlap
Checked nominal mating geometry
Rigid hardware checks
58 nearby pairs; no unintended
interference
Modeled component fit, with documented
reference limits
Original PCB static sweep
306 solids preserved; pass
Fit against the supplied PCB geometry
Control positions at stops
Pass; minimum checked PCB gap 1.1
No checked cap overlap at nominal stop
positions
Continuous PTT sweep
Pass through 0.6 inward travel
Straight rigid translation excluding intentional
pad compression
Export association
Hashes and volume association pass
Delivered parts linked to checked assembly
inputs
The overlap reporting threshold is 0.001 cubic millimetres. A broad-phase bounding test skips pairs that
cannot exceed that threshold. Dedicated stop distances were measured separately. The continuous PTT
sweep covers every intermediate axial position; it does not cover off-axis tilt or deformed parts.
These results do not establish tolerance capability, structural strength, complete populated-board coverage, harness fit,
powered functionality, RF performance or production readiness. Full report files, tested input hashes and the archive manifest
are retained in the R5 package.
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R5 validation reports and exact-file association; current nominal geometry and motion checks

PAGE 38
WALKIE ONE   /   CONCEPT 21.2   /   ASTRA R5
EVIDENCE AND QUALIFICATION
Priority issues for the engineering review
Priority
Issue
Recommended closure evidence
Before final fit
Missing cellular body and uncertain
populated coverage
Inspect real board; update component coverage and
repeat collision/packing checks
Before final fit
Mated plugs and harness are unmodeled
Approved harness and plug envelopes;
demonstrated closure and service slack
Before functional
sample
Board memory, pinouts and volume
firmware
Verified hardware identity, schematic mapping,
compatible build and all key behavior
Before mechanical
release
PTT/USB web and J3 local wall
Physical stiffness/fit inspection and accepted
material/process result
Before durability
release
PTT force, tilt, stops and pad recovery
Force/displacement, multi-position press and
endurance results
Before powered
release
Battery, charging, thermal and RF behavior
Electrical and RF owner signoff on installed system
tests
Before appearance
release
Materials, adhesives and rear artwork
Approved swatches, bond tests and marking sample
Agree a named owner, due date and required evidence for each issue at the first review. Treat a missing
input as an explicit hold on the affected release decision, rather than silently filling it with a guessed
connector assignment, component dimension or supplier capability.
Record each closure decision against the delivered CAD and the actual prototype. Keep the dimensional, appearance and
functional acceptance records associated with the same configuration.
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R5 CAD and handoff evidence

PAGE 39
WALKIE ONE   /   CONCEPT 21.2   /   ASTRA R5
EVIDENCE AND QUALIFICATION
Physical acceptance and test records
Test family
Method to agree
Evidence to record
Incoming / fit
Measure actual hardware and assemble the
intended stack
Revision photos, dimensions, closure and
contact findings
Controls
Press PTT ends/center; test every key and
tolerance state
Force-displacement, switch closure, return and
retention
USB / service
Use intended plug families and open the cover
Mate force, cable clearance, web condition and
service demonstration
Power / thermal
Approved charging, voice and radio operating
states
Voltages, currents, temperatures and cell
condition
Audio / indicator
Compare enclosure to open references under
intended conditions
Voice intelligibility, buzz/leakage, level and light
visibility
RF
Test final antenna/harness and representative
grips
Installed performance and agreed compliance
route
Durability
Agreed drop, twist, cycling, abrasion and
environment
Conditions, sample count, failures and post-test
function
Cosmetics / assembly
Inspect final colors, texture, grille and marking
Approved master sample, deviation log and
serial traceability
Numerical force, drop, temperature, acoustic, ingress and endurance targets have not yet been approved.
Set them with the product and engineering owners before testing. The table is a proposed acceptance plan,
not a record of passing results or a claim of certification.
For each test, record unit serial number, mechanical revision, board revision, firmware identity, materials, setup, measurement
equipment, conditions, result and disposition. Photograph failures and link corrective actions to the next CAD/BOM revision.
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R5 CAD and handoff evidence

PAGE 40
WALKIE ONE   /   CONCEPT 21.2   /   ASTRA R5
SUPPLIER QUOTATION
Proposed manufacturing development
route
Stage
Purpose
Suggested deliverables
Engineering review
Agree scope and remove
unknowns
Marked STEP review, component reconciliation,
process/tolerance plan
Fit article
Validate geometry and service
access
Unfinished or minimally finished rigid parts, real components, fit
report
Functional prototype
Demonstrate all intended
behavior
Approved harness/daughterboards, firmware,
power/audio/RF/control tests
Appearance sample
Approve the intended product
finish
Color/texture masters, grip and adhesive process, grille and
rear marking
Pilot build
Test repeatable assembly and
inspection
Work instructions, fixtures, inspection records and yield findings
Production tooling
Develop a stable process at
agreed volume
Draft/undercut review, tool design, first articles and signed
release
Our suggested initial structural route is a PA12 additive fit sample, subject to Rapid confirming a suitable
material and process. Rapid publicly lists SLS, urethane casting, presentation finishing and injection
molding. Those services are relevant options for review, not a quotation or confirmation that this exact
design is producible by each route. [W1-W5]
A cast route needs its own insert, shrinkage and material assessment. Injection molding needs a new
tool-oriented DFM stage; the current retained controls, side openings and internal supports are not released
mold designs. Agree parting lines, draft, manufacturing locations and first-article acceptance before tooling
release.
Do not use generic web lead times or process accuracy statements as the acceptance criteria for this assembly. Request a
part-specific quotation and capability response.
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Proposed development sequence; Rapid public service pages [W1-W5], accessed 04 September 2026

PAGE 41
WALKIE ONE   /   CONCEPT 21.2   /   ASTRA R5
SUPPLIER QUOTATION
Quotation scope and supplier response
Quote separately
State in the response
DFM and component reconciliation
Included reviews, required physical inputs, deliverables and exclusions
Mechanical parts and finishing
Process/grade per part family, build orientation, tolerances, color/texture approval
Purchased components
Customer supplied versus supplier procured; exact source and revision
Electrical and firmware work
Responsible party, daughterboard/harness scope, bring-up and programming
Assembly and testing
Fixtures, labor, inspection, functional tests and traceability
Tooling and scale options
Tool ownership, maintenance, production locations and revision costs
Delivery
Schedule assumptions, packaging, documentation and shipping scope
Suggested estimating scenarios. Provide budgetary scenarios for 5 engineering prototypes, 25 pilot
units, and optional 100/500-unit production quantities if useful to your process selection. These are
comparison quantities for discussion, not a purchase order or committed demand.
Separate alternatives. Identify feasible manufacturing routes and any differences in materials, finish,
production location and inspection scope. Show one-time engineering/tooling charges separately from unit
costs. State what changes or unresolved inputs could change price and lead time.
Response requested. Return an assumptions list, proposed deviations, component/sample needs, a milestone plan,
first-article inspection approach and a clear list of work that Rapid can perform directly versus work requiring another owner.
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R5 CAD and handoff evidence

PAGE 42
WALKIE ONE   /   CONCEPT 21.2   /   ASTRA R5
CONFIGURATION AND DELIVERY
Release control and sharing instructions
Current engineering package: Walkie One Concept 21.2 - Astra R5. The CAD configuration is
ASTRA_21_2_R5_SOAP_28p8. Share the complete Rapid Products Handoff ZIP; the matching R5 CAD archive
includes geometry, editable source, component inputs, artwork, manufacturing notes, BOM and validation
evidence. START_HERE.md identifies the exact filenames.
Artifact
Use
This PDF
Supplier review, orientation, critical requirements and proposed build/test scope
Current CAD ZIP
Authoritative delivered geometry and exact validation association
CAD view library
High-resolution report images and camera/visibility manifest
Sharing manifest
File sizes and SHA-256 hashes for this report package
Before a revision. Record the owner, reason and affected parts. Preserve the source PCB at scale 1.
Recheck affected interfaces, the 30 mm finished maximum, cap travel, artwork and complete
connector/harness fit. Update the BOM, drawings, rendered views and test evidence together.
Before tooling or shipment. Obtain approved process-specific drawings, material grades,
electrical/harness data, firmware, inspection criteria and completed physical qualification. Separate
acceptance of appearance from acceptance of functionality and manufacturing readiness.
Delivery records. Supply an as-built BOM, mechanical/PCB/firmware revisions, deviations, inspection
results, serial-level functional records, material/finish references and service instructions. Packaging and
shipping conditions for the final powered product must be agreed as part of the supplier scope.
Review acceptance and fabrication authorization should identify the exact CAD, BOM, material and process revisions. The
estimating scenarios in this report are not purchase quantities or production-release approval.
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R5 CAD and handoff evidence

PAGE 43
WALKIE ONE   /   CONCEPT 21.2   /   ASTRA R5
COMPLETE PARTS SCHEDULES
Custom parts schedule 1
One occurrence of each listed custom part is modeled. IDs match BOM_R5.csv; the full CSV retains exact
filenames, volumes and material/status notes.
ID
Part
Family
Qty
Complete part bounds X x Y x Z
C001
Battery lid foam pad 1
Foam
1
4.00 x 2.50 x 4.00
C002
Battery lid foam pad 2
Foam
1
4.00 x 2.50 x 4.00
C003
Battery lid foam pad 3
Foam
1
4.00 x 2.50 x 4.00
C004
Battery tray foam
Foam
1
52.00 x 0.50 x 28.00
C005
Front switch FR4 carrier
FR4
1
52.00 x 1.60 x 27.00
C006
LED FR4 carrier
FR4
1
26.00 x 1.60 x 11.70
C007
Left PTT FR4 carrier
FR4
1
6.00 x 1.60 x 84.00
C008
Right volume FR4 carrier
FR4
1
6.00 x 1.60 x 50.00
C009
Front chassis
Rigid polymer
1
88.00 x 17.40 x 150.00
C010
Front grip PSA patch 1
Adhesive
1
0.10 x 8.00 x 6.00
Reading the dimensions. These are the complete installed-coordinate bounding boxes, including flanges,
tabs, pads or hidden features. They are not visible dimensions, stock sizes or manufacturing tolerances. For
example, the PTT is 72 mm visibly long while its complete R5 cap bounds extend 77.5 mm in Z.
Material status. Families express the proposed prototype intent. Exact grade, hardness, thickness tolerance, adhesive system
and finish remain subject to supplier approval and physical testing. Foam filenames describe free-to-compressed thickness;
delivered CAD represents the installed condition.
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BOM_R5.csv; exact per-part STEP bounding boxes and measured nominal volumes

PAGE 44
WALKIE ONE   /   CONCEPT 21.2   /   ASTRA R5
COMPLETE PARTS SCHEDULES
Custom parts schedule 2
One occurrence of each listed custom part is modeled. IDs match BOM_R5.csv; the full CSV retains exact
filenames, volumes and material/status notes.
ID
Part
Family
Qty
Complete part bounds X x Y x Z
C011
Front grip PSA patch 2
Adhesive
1
0.10 x 8.00 x 6.00
C012
Front grip PSA patch 3
Adhesive
1
0.10 x 8.00 x 16.00
C013
Front grip PSA patch 4
Adhesive
1
0.10 x 8.00 x 4.00
C014
Front grip PSA patch 5
Adhesive
1
0.10 x 8.00 x 14.00
C015
Front grip skin
Elastomer
1
90.40 x 18.60 x 152.40
C016
W grille plate
Metal
1
61.70 x 0.80 x 63.70
C017
Grille perimeter PSA
Adhesive
1
61.70 x 0.10 x 63.70
C018
LTE backing adhesive
Adhesive
1
21.00 x 0.20 x 96.00
C019
Microphone clamp bracket
Rigid polymer
1
6.00 x 2.00 x 23.90
C020
Microphone duct gasket
Foam
1
6.00 x 1.90 x 6.00
Reading the dimensions. These are the complete installed-coordinate bounding boxes, including flanges,
tabs, pads or hidden features. They are not visible dimensions, stock sizes or manufacturing tolerances. For
example, the PTT is 72 mm visibly long while its complete R5 cap bounds extend 77.5 mm in Z.
Material status. Families express the proposed prototype intent. Exact grade, hardness, thickness tolerance, adhesive system
and finish remain subject to supplier approval and physical testing. Foam filenames describe free-to-compressed thickness;
delivered CAD represents the installed condition.
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BOM_R5.csv; exact per-part STEP bounding boxes and measured nominal volumes

PAGE 45
WALKIE ONE   /   CONCEPT 21.2   /   ASTRA R5
COMPLETE PARTS SCHEDULES
Custom parts schedule 3
One occurrence of each listed custom part is modeled. IDs match BOM_R5.csv; the full CSV retains exact
filenames, volumes and material/status notes.
ID
Part
Family
Qty
Complete part bounds X x Y x Z
C021
Microphone foam strip 1
Foam
1
6.00 x 2.80 x 3.00
C022
Microphone foam strip 2
Foam
1
6.00 x 2.80 x 3.00
C023
PCB clamp silicone pad 1
Silicone
1
2.00 x 0.80 x 6.00
C024
PCB clamp silicone pad 2
Silicone
1
2.00 x 0.80 x 6.00
C025
PCB clamp silicone pad 3
Silicone
1
1.50 x 0.80 x 6.00
C026
PCB clamp silicone pad 4
Silicone
1
1.50 x 0.80 x 6.00
C027
Front action cap
Rigid polymer
1
37.00 x 9.60 x 37.00
C028
Front action silicone pad
Silicone
1
8.00 x 1.50 x 8.00
C029
Orange PTT cap
Rigid polymer
1
6.00 x 16.30 x 77.50
C030
PTT silicone pad 1
Silicone
1
2.30 x 5.00 x 5.00
Reading the dimensions. These are the complete installed-coordinate bounding boxes, including flanges,
tabs, pads or hidden features. They are not visible dimensions, stock sizes or manufacturing tolerances. For
example, the PTT is 72 mm visibly long while its complete R5 cap bounds extend 77.5 mm in Z.
Material status. Families express the proposed prototype intent. Exact grade, hardness, thickness tolerance, adhesive system
and finish remain subject to supplier approval and physical testing. Foam filenames describe free-to-compressed thickness;
delivered CAD represents the installed condition.
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BOM_R5.csv; exact per-part STEP bounding boxes and measured nominal volumes

PAGE 46
WALKIE ONE   /   CONCEPT 21.2   /   ASTRA R5
COMPLETE PARTS SCHEDULES
Custom parts schedule 4
One occurrence of each listed custom part is modeled. IDs match BOM_R5.csv; the full CSV retains exact
filenames, volumes and material/status notes.
ID
Part
Family
Qty
Complete part bounds X x Y x Z
C031
PTT silicone pad 2
Silicone
1
2.30 x 5.00 x 5.00
C032
Rear grip PSA panel
Adhesive
1
50.00 x 0.10 x 50.00
C033
Inscribed rear grip skin
Elastomer
1
90.40 x 10.20 x 152.40
C034
Rear service cover
Rigid polymer
1
88.00 x 9.00 x 150.00
C035
Speaker rim gasket
Foam
1
40.00 x 1.00 x 40.00
C036
Clear diffusing status lens
Optical polymer
1
11.00 x 4.20 x 4.50
C037
Volume minus cap
Rigid polymer
1
5.60 x 16.10 x 23.00
C038
Volume minus pad
Silicone
1
2.30 x 5.00 x 5.00
C039
Volume plus cap
Rigid polymer
1
5.60 x 16.10 x 23.00
C040
Volume plus pad
Silicone
1
2.30 x 5.00 x 5.00
Reading the dimensions. These are the complete installed-coordinate bounding boxes, including flanges,
tabs, pads or hidden features. They are not visible dimensions, stock sizes or manufacturing tolerances. For
example, the PTT is 72 mm visibly long while its complete R5 cap bounds extend 77.5 mm in Z.
Material status. Families express the proposed prototype intent. Exact grade, hardness, thickness tolerance, adhesive system
and finish remain subject to supplier approval and physical testing. Foam filenames describe free-to-compressed thickness;
delivered CAD represents the installed condition.
Engineering review and prototype quotation   |   04 September 2026
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BOM_R5.csv; exact per-part STEP bounding boxes and measured nominal volumes

PAGE 47
WALKIE ONE   /   CONCEPT 21.2   /   ASTRA R5
COMPLETE PARTS SCHEDULES
Purchased components and unresolved
items
ID
Component or work item
Qty
Release note
H001
ruthex RX-M2x4 insert
14
Thermoplastic heat-set only; cast thermoset requires another
engineered process
H002
Accu SSCF-M2-12-A2
4
Closure; torque/insert process trial required
H003
Accu SSCF-M2-6-A2
10
Switch/LED carriers and microphone bracket
E001
Original customer PCB
1
306 source solids; actual populated coverage and memory
variant unconfirmed
E002
Adafruit 2011 battery
1
Confirm polarity, protection, charging, thickness and swelling
E003
Same Sky CMS-40504N-L152 speaker
1
4 ohm; audio integration and enclosed response require
testing
E004
Adafruit 3421 microphone breakout
1
Verify actual acoustic-port revision/alignment
E005
Omron B3F-3150
4
2 PTT + 1 volume up + 1 volume down
E006
Omron B3F-4000
1
Front action switch
E007
Kingbright WP154A4SUREQBFZGW
1
Source mesh incomplete; conservative nominal body used in
clearance checks
E008
Taoglas FXUB63.07.0150C
1
150 mm coax; RF port and installed tuning unconfirmed
U001
Cellular module / populated-board
reconciliation
TBD
24 x 24 x 2.4 keepout only; not counted as installed hardware
U002
Approved daughterboards and wiring
harness
TBD
Electrical design, approved harness routing and service slack
required
The four B3F-3150 switches comprise two beneath the PTT and one per volume key. Confirm procurement quantities from this
schedule. Keep the assumed cellular keepout separate from actual purchased/installed hardware.
Engineering review and prototype quotation   |   04 September 2026
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BOM_R5.csv; component references; missing cellular coverage remains unresolved

PAGE 48
WALKIE ONE   /   CONCEPT 21.2   /   ASTRA R5
COMPLETE PARTS SCHEDULES
Complete fastener location schedule
All positions are in the body coordinate frame. Top Y is the boss seating datum. Tip margin is the nominal
axial distance between the screw tip and the modeled pilot floor, not thread engagement or a torque
qualification.
Mount
X
Z
Top Y
Bore
depth
Screw
Tip margin
closure +34 +62
34.00
61.50
4.20
6.0
M2 x 12
1.2
closure -34 +62
-34.00
61.50
4.20
6.0
M2 x 12
1.2
closure +34 -62
34.00
-61.50
4.20
6.0
M2 x 12
1.2
closure -34 -62
-34.00
-61.50
4.20
6.0
M2 x 12
1.2
front carrier +22
22.50
-32.00
-4.20
6.0
M2 x 6
1.6
front carrier -22
-22.50
-32.00
-4.20
6.0
M2 x 6
1.6
left carrier -36
-33.85
-36.50
-7.20
5.0
M2 x 6
0.6
left carrier +40
-33.85
40.50
-7.20
5.0
M2 x 6
0.6
right carrier -16
33.85
-16.00
-7.20
5.0
M2 x 6
0.6
right carrier +26
33.85
26.00
-7.20
5.0
M2 x 6
0.6
led carrier +10
10.00
-2.50
-1.20
6.0
M2 x 6
1.6
led carrier -10
-10.00
-2.50
-1.20
6.0
M2 x 6
1.6
mic bracket -46
22.00
-46.30
-5.70
6.0
M2 x 6
2.0
mic bracket -66
22.00
-65.80
-5.70
6.0
M2 x 6
2.0
There are 14 insert locations and 14 screws. The four closure positions use M2 x 12; the ten carrier/bracket
positions use M2 x 6. Use the full FASTENER_STACK_R5.csv for clamped thickness, screw tip Y, boss height
and pilot-floor relationship to the inner wall.
Do not infer tightening torque from nominal geometry. Inspect pilot size, residual floor, insert alignment, seating, pullout and
repeated service behavior in the chosen process. A different insert or screw requires a recorded mechanical review.
Engineering review and prototype quotation   |   04 September 2026
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FASTENER_STACK_R5.csv; all dimensions mm; process-specific installation settings not released

PAGE 49
WALKIE ONE   /   CONCEPT 21.2   /   ASTRA R5
SOURCES AND TRACEABILITY
Source index and evidence files
Reference
File or source
S1 Current assembly
cad/ASTRA_21_2_R5_SOAP_28p8_FULL_ASSEMBLY.step
S2 Mechanical / exploded
Matching MECHANICAL.step and EXPLODED.step in cad/
S3 Individual parts
cad/custom_parts/; exact names in docs/BOM_R5.csv
S4 PCB and component
references
cad/references/; original inputs retained in inputs/
S5 Mechanical evidence
validation/MECHANICAL_CORE_CHECKS.json; pcb_interference_FINAL.json;
pcb_motion_FINAL.json
S6 Centering and sweep
validation/CENTERED_PTT_SWEEP.json and .step; PTT_USB_WEB.json
S7 Export provenance
independent_step_validation.json; mesh_validation.json; VALIDATION_ASSOCIATION.json;
MANIFEST_SHA256.json
S8 Component and
software evidence
COMPONENT_REFERENCE_BASIS.json; firmware_source_provenance.json; component and
vendor references
S9 Source and artwork
source/; artwork/grille_W_pattern_flat.dxf; rear_inscription_artwork_rear_view.svg
External supplier references accessed 04 September 2026
[W1] Rapid Product Solutions home and contact
[W2] Selective Laser Sintering service
[W3] Urethane Castings service
[W4] Injection Molding service
[W5] Concept and Presentation Models finishing services
[W6] Walkie One design system and approved wordmark
Source documents are engineering references; current customer requirements and the supplied CAD govern this report. Vendor
specifications retained in the input archive require revision confirmation at procurement. No commercial terms, material stock,
supplier acceptance or lead time is inferred from a website listing.
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R5 CAD and handoff evidence
