# Walkie One 28.2 — terminal clearance resolved in CAD

The two rear terminals of the upper volume switch now turn 90° toward the front of the device. This removes their intersections with the battery guide and liner without moving the approved buttons or changing the battery, housings, cradles, switch housing, plunger or travel stops.

**This is a proposed formed-terminal assembly configuration. The selected switch remains an estimated reference, and the purchased switch's ability to accept the bend has not been verified. CAD clearance is resolved; physical hardware qualification remains required.**

## Deliverables

- [Native Autodesk Fusion model](../CAD/Walkie_One_28_2_TERMINAL_CLEARANCE_RESOLVED.f3d)
- [Reference assembly STEP](../CAD/Walkie_One_28_2_REFERENCE_ASSEMBLY_TERMINAL_CLEARANCE.step)
- [Estimated formed-switch STEP](../CAD/Assembly_References_NOT_FOR_PRINTING/Estimated_Upper_Switch_Formed_Terminal_Reference.step)
- [Reserved terminal, solder and insulation envelopes](../CAD/Assembly_References_NOT_FOR_PRINTING/Upper_Terminal_Solder_Insulation_Envelope.step)

The last two files describe assembly/reference geometry. They are not parts to print or manufacture as switches. The STEP assembly excludes the hidden clearance gauges; the F3D retains them as separate hidden components.

## Measured clearance

Minimum distances were measured on native Fusion bodies after the change. Values apply to each of the two formed terminals and their corresponding larger reserved envelopes.

| Target | Formed metal | Solder/insulation envelope |
| --- | ---: | ---: |
| Rear battery guide/shell | 0.69 mm | 0.29 mm |
| Battery-side liner | 2.09 mm | 1.69 mm |
| Battery reference body | 2.35 mm | 1.95 mm |

There are zero intersections between the upper-switch solids and other physical assembly solids, including the other switch bodies. All four upper terminal/solder envelopes also clear surrounding parts and each other. Both controls pass the five checked inward travel positions: 0, 0.15, 0.225, 0.40 and 0.45 mm. These are rigid-body checks at sampled positions, not force or continuous-motion qualification.

The approved placement remains: volume-up center Y=40.6 mm, volume-down center Y=11.6 mm, 29 mm pitch, and upper carrier top Y=50 mm at the shoulder line. Neither exterior button size nor placement changed in this fix.

## Proposed terminal form

Only the two rear terminals of the upper volume switch change. The two forward terminals stay straight. In assembly coordinates, the formed terminals lie at Y=37.35 and Y=43.85 mm and turn toward +Z.

| Parameter | Nominal model value |
| --- | ---: |
| Developed terminal centerline length | 3.50 mm |
| Terminal cross-section | 0.90 × 0.30 mm |
| Centerline bend radius | 0.60 mm |
| Inside bend radius | 0.45 mm |
| Straight section before bend | 0.80 mm |
| Arc length | 0.94248 mm |
| Straight tail after bend | 1.75752 mm |
| Formed tail center X | 32.50 mm |
| Formed tail end Z | -9.09248 mm |
| Reserved solder/insulation width and thickness | 1.40 × 1.10 mm |

Each terminal retains the original estimated metal volume, 0.945 mm³. No terminal length was deleted to obtain clearance. The larger envelopes follow the proposed route and retain the original cross-sectional allowance, with an additional 0.55 mm beyond the formed free end. Keep any solder joint and insulation within these reserved envelopes.

This form must be checked on the actual switch before adoption. Confirm terminal material, available free length, bend acceptability, insulation, electrical continuity and operation after forming. The model does not establish those hardware properties or the complete wire route to the PCB. If the supplier does not permit this form, a compatible terminal configuration or a different internal layout is required; do not treat the estimated reference as proof that a purchased switch can be reshaped.

## Verification and history

- All 334 occurrences, 590 solid bodies and 1,360 inherited supplier surface bodies matched when the saved F3D was reopened in Fusion.
- 586 of 590 solids retain the previous approved 28.2 geometry and placements. Only two estimated terminal bodies and their two hidden clearance gauges changed.
- All 10 solids in the two reference STEP exports independently pass Open CASCADE validity and volume comparison checks.
- The prior markup-aligned 28.2 file remains unchanged, verified by its saved SHA-256. This revision keeps the existing guide relief and relocated grip pad.
- Detailed results are in `../Verification/Terminal_Clearance/`; the native Fusion Python operations are in `../Source_History/`. Replaying the operations requires the prior saved 28.2 source and Autodesk Fusion.
- This revision remains a fit prototype. It does not qualify manufacturing tolerances, switch forming, material strength, insulation, RF or electrical performance.

![Proposed formed rear terminal, side profile](../Previews/28_2_switch_form_side_profile.png)

![Upper control assembly](../Previews/28_2_upper_control_clearance.png)

![Approved exterior retained](../Previews/28_2_exterior.png)