WALKIE ONE v12.3 — FUSION NO-STACK INTERNAL FIT AUDIT Active document: Untitled Coincident faces excluded; reported volumes are solid-volume overlap. The audit modifies only this unsaved Fusion session; the exported F3D is unchanged. A. PRINTED PARTS, BUTTONS, AND FULLY INSERTED USB-C PLUG FRONT SHELL:1 vs BACK SHELL:1: 0 overlap(s), 0.000000 mm^3 — PASS FRONT SHELL:1 vs FRONT ACTION BUTTON:1: 0 overlap(s), 0.000000 mm^3 — PASS FRONT SHELL:1 vs STATUS LIGHT LENS:1: 1 overlap(s), 0.592018 mm^3 — INTENTIONAL RETENTION PRESS-FIT FRONT SHELL:1 vs FRONT SWITCH CLAMP:1: 0 overlap(s), 0.000000 mm^3 — PASS BACK SHELL:1 vs FRONT SWITCH CLAMP:1: 0 overlap(s), 0.000000 mm^3 — PASS FRONT SHELL:1 vs LEFT PTT BUTTON:1: 0 overlap(s), 0.000000 mm^3 — PASS BACK SHELL:1 vs LEFT PTT BUTTON:1: 0 overlap(s), 0.000000 mm^3 — PASS FRONT SHELL:1 vs VOLUME UP BUTTON:1: 0 overlap(s), 0.000000 mm^3 — PASS BACK SHELL:1 vs VOLUME UP BUTTON:1: 0 overlap(s), 0.000000 mm^3 — PASS FRONT SHELL:1 vs VOLUME DOWN BUTTON:1: 0 overlap(s), 0.000000 mm^3 — PASS BACK SHELL:1 vs VOLUME DOWN BUTTON:1: 0 overlap(s), 0.000000 mm^3 — PASS FRONT SHELL:1 vs FITCHECK — USB-C PLUG FULLY INSERTED:1: 0 overlap(s), 0.000000 mm^3 — PASS BACK SHELL:1 vs FITCHECK — USB-C PLUG FULLY INSERTED:1: 0 overlap(s), 0.000000 mm^3 — PASS FRONT ACTION BUTTON:1 vs FITCHECK — FRONT SWITCH — OMRON B3F-4000:1: 0 overlap(s), 0.000000 mm^3 — PASS LEFT PTT BUTTON:1 vs FITCHECK — PTT SWITCH — OMRON B3F-3150:1: 0 overlap(s), 0.000000 mm^3 — PASS VOLUME UP BUTTON:1 vs FITCHECK — VOLUME UP SWITCH — OMRON B3F-3150:1: 0 overlap(s), 0.000000 mm^3 — PASS VOLUME DOWN BUTTON:1 vs FITCHECK — VOLUME DOWN SWITCH — OMRON B3F-3150:1: 0 overlap(s), 0.000000 mm^3 — PASS STATUS LIGHT LENS:1 vs FITCHECK — RGB LED — KINGBRIGHT WP154A4SUREQBFZGW:1: 0 overlap(s), 0.000000 mm^3 — PASS Lens classification: the modeled collector is retained by a nominal Ø5.4/Ø5.3 mm press fit. This is not electronic-component interference; physical print-process validation remains required. B. RIGID HARDWARE VS FRONT AND BACK SHELLS — EXACT BODY TEST FITCHECK — BATTERY — ADAFRUIT 2011:1 conversion-placement delta: 0.010000 mm FITCHECK — BATTERY — ADAFRUIT 2011:1: 0 overlap(s), 0.000000 mm^3 — PASS FITCHECK — SPEAKER — SAMESKY CMS-40504N-L152:1 conversion-placement delta: 0.010000 mm FITCHECK — SPEAKER — SAMESKY CMS-40504N-L152:1: 0 overlap(s), 0.000000 mm^3 — PASS FITCHECK — LTE ANTENNA — TAOGLAS FXUB63:1 conversion-placement delta: 0.010000 mm FITCHECK — LTE ANTENNA — TAOGLAS FXUB63:1: 0 overlap(s), 0.000000 mm^3 — PASS FITCHECK — MICROPHONE — ADAFRUIT 3421:1 conversion-placement delta: 0.015000 mm FITCHECK — MICROPHONE — ADAFRUIT 3421:1: 0 overlap(s), 0.000000 mm^3 — PASS FITCHECK — RGB LED — KINGBRIGHT WP154A4SUREQBFZGW:1 conversion-placement delta: 0.010000 mm FITCHECK — RGB LED — KINGBRIGHT WP154A4SUREQBFZGW:1: 0 overlap(s), 0.000000 mm^3 — PASS FITCHECK — FRONT SWITCH — OMRON B3F-4000:1 conversion-placement delta: 0.010000 mm FITCHECK — FRONT SWITCH — OMRON B3F-4000:1: 0 overlap(s), 0.000000 mm^3 — PASS FITCHECK — PTT SWITCH — OMRON B3F-3150:1 conversion-placement delta: 0.010000 mm FITCHECK — PTT SWITCH — OMRON B3F-3150:1: 0 overlap(s), 0.000000 mm^3 — PASS FITCHECK — VOLUME UP SWITCH — OMRON B3F-3150:1 conversion-placement delta: 0.010000 mm FITCHECK — VOLUME UP SWITCH — OMRON B3F-3150:1: 0 overlap(s), 0.000000 mm^3 — PASS FITCHECK — VOLUME DOWN SWITCH — OMRON B3F-3150:1 conversion-placement delta: 0.010000 mm FITCHECK — VOLUME DOWN SWITCH — OMRON B3F-3150:1: 0 overlap(s), 0.000000 mm^3 — PASS FITCHECK — PCB — SUPPLIED STEP:1: 0 overlap(s), 0.000000 mm^3 — PASS C. VERIFIED RIGID-HARDWARE ENVELOPE FITCHECK — BATTERY — ADAFRUIT 2011:1: x -30.01..30.01, y 28.27..64.29, z -16.57..-8.15 — INSIDE FITCHECK — SPEAKER — SAMESKY CMS-40504N-L152:1: x -20.01..20.01, y 15.09..68.91, z -7.66..-2.64 — INSIDE FITCHECK — LTE ANTENNA — TAOGLAS FXUB63:1: x -10.51..10.51, y -34.51..67.51, z -21.29..-20.92 — INSIDE FITCHECK — MICROPHONE — ADAFRUIT 3421:1: x 5.73..22.27, y -20.36..-7.64, z -4.86..-3.01 — INSIDE FITCHECK — RGB LED — KINGBRIGHT WP154A4SUREQBFZGW:1: x -2.96..2.96, y 2.04..7.96, z -14.31..-1.69 — INSIDE FITCHECK — FRONT SWITCH — OMRON B3F-4000:1: x -6.01..6.01, y -53.01..-40.99, z -10.61..-2.79 — INSIDE FITCHECK — PTT SWITCH — OMRON B3F-3150:1: x -38.51..-32.34, y 7.64..16.36, z -18.21..-8.29 — INSIDE FITCHECK — VOLUME UP SWITCH — OMRON B3F-3150:1: x 32.34..38.51, y 18.64..27.36, z -18.21..-8.29 — INSIDE FITCHECK — VOLUME DOWN SWITCH — OMRON B3F-3150:1: x 32.34..38.51, y -10.36..-1.64, z -18.21..-8.29 — INSIDE FITCHECK — PCB — SUPPLIED STEP:1: x -30.02..30.02, y -58.81..26.98, z -20.42..-10.86 — INSIDE D. RIGID HARDWARE-TO-HARDWARE EXACT INTERFERENCE CLEAR AFTER EXACT TEST: FITCHECK — RGB LED — KINGBRIGHT WP154A4SUREQBFZGW:1 vs FITCHECK — PCB — SUPPLIED STEP:1 All bounding-box candidates are clear in exact solid testing. E. NO-STACK SEPARATION Battery plan range Y: 28.27..64.29 mm PCB plan range Y: -58.81..26.98 mm Battery-to-PCB measured plan gap: 1.29 mm — PASS Nominal derived plan gap: 1.30 mm = 0.25 + 0.80 + 0.25 mm Front-switch-to-PCB depth gap: 0.25 mm — PASS F. BUTTON MOTION — FULL MODELED HARD TRAVEL Front action: shell overlaps 0 (0.000000 mm^3); actuator engagement 1 (16.775257 mm^3) — PASS PTT: shell overlaps 0 (0.000000 mm^3); actuator engagement 1 (1.818662 mm^3) — PASS Volume up: shell overlaps 0 (0.000000 mm^3); actuator engagement 1 (1.818662 mm^3) — PASS Volume down: shell overlaps 0 (0.000000 mm^3); actuator engagement 1 (1.818662 mm^3) — PASS Rest gap 0.14 mm; side travel 0.65 mm; front travel 0.70 mm. Motion test uses translated transient copies; the live assembly remains at rest. G. SIX-DIRECTION POSITIVE LOCATION PCB: ±X side rails; -Y lower stops; +Y shared divider; -Z front ledges; +Z back clips — PASS USB-C socket: PCB solder anchors locate ±Y/±Z and outward extraction; case-backed bridge limits inward insertion load without touching pins — PASS Battery: ±X side rails; -Y shared divider; +Y split top-rail lands; -Z rounded pads; +Z rear pads — PASS Speaker: circumferential seat/clips in ±X/±Y; front seat and rear snap lips in ±Z — PASS Microphone: four-sided breakout pocket in ±X/±Y; front seat and snap lips in ±Z — PASS LED: guide bore/hooks in ±X/±Y; optical stop and flange hooks in ±Z — PASS LTE antenna: side rails in ±X; end stops in ±Y; front lips and rear lands in ±Z — PASS Front switch: four corner guides in ±X/±Y; reaction bridge and removable clamp in ±Z — PASS PTT switch: actuator shoulder/backstop in ±X; side rails in ±Y; split floor/roof in ±Z — PASS Volume-up switch: actuator shoulder/backstop in ±X; side rails in ±Y; split floor/roof in ±Z — PASS Volume-down switch: actuator shoulder/backstop in ±X; side rails in ±Y; split floor/roof in ±Z — PASS H. WALL, EXTERIOR-SKIN, ROUTING, AND ASSEMBLY AUDIT Nominal wall: 2.20 mm; side-control recess floor: 1.45 mm; rear saddle floor: 1.50 mm; wordmark floor: 1.85 mm; microphone gasket floor: 1.90 mm — PASS Minimum structural rail: 1.20 mm; open cable clear width: 5.30 mm for measured 4.80 mm lead envelope — PASS PCB front support centers: ±32.75 mm, derived behind the 10 mm perimeter roll with 0.25 mm reserve — PASS USB-C reaction bridge: exact shell rear X 22.4773 mm to bridge face X 22.2773 mm = 0.20 mm clearance — PASS USB-C pin protection: exact signal-pin top Z 14.4599 mm to bridge start Z 14.7099 mm = 0.25 mm clearance — PASS USB-C load path: 2.20 mm bridge overlaps the rear-wall solid by 0.10 mm; exact PCB-versus-shell interference remains zero — PASS Opaque orthographic exterior views: 6 of 6 — PASS Cable channel: open at both ends; no trapped-support cavity; six captive tabs keep leads away from seam/screws — PASS Battery removal relief preserves two symmetric +Y retention lands; soft-pad pockets remain outside antenna X envelope — PASS Assembly order remains front controls/hardware, switches, PCB, rear antenna, battery, cable loading, then straight back-shell closure; USB bridge descends behind the socket — PASS I. SUMMARY Unintended printed-part/button/USB overlaps: 0 Intentional lens retention overlaps: 1 (0.592018 mm^3) Rigid hardware/shell overlaps: 0 Rigid hardware/shell overlap volume: 0.000000 mm^3 Rigid components outside verified envelope: 0 Hardware bounding-box candidates exactly tested: 1 Exact rigid hardware-to-hardware overlaps: 0 Button motion failures: 0 Exterior audit view failures: 0 Physical cable-routing and process-tolerance validation: REQUIRED