# Dimensions, sources and assumptions

## Source distinction

| Item | Basis used | What is still a physical check |
|---|---|---|
| Case | Original R3.4 CAD, nominal78×150×24mm; original outer faces/opening outlines compared | Print shrinkage and actual outer dimensions |
| PCB | Supplied CAD60×80mm, source laminate1.33mm plus actual component model and separate24×24×2.4mm U6 reference; support stack reserves1.80mm | Received board thickness, module height, solder tips and actual USB seating |
| Battery | Agreed maximum62×38.5×8.5mm from Adafruit-linked pack specification; nominal product page60×36×7mm is not the design limit | Current protected/taped lead exit, wrapping and natural slack dressing |
| Microphone | Blue SPH0645 board geometry and published footprint; KR-D catalog connector envelope | Received solder row, low-profile insulation, SEL wiring and acoustic performance |
| PH / KR-D plugs | Manufacturer catalog mated envelopes; all contacts and wire insulation specified in harness instructions | Received connector variant, seating/latch position and professional termination |
| Switches | Supplied nominal LIDUOLE proxies; selected0.50mm play /0.45mm side-control stops | Actual terminal pairing, operating travel/force, overtravel, release and edge pressing |
| Speaker / LED / antenna | Selected-part reference CAD / manufacturer drawings | Speaker terminal orientation, LED formed leads/brightness, antenna adhesion and RF operation |
| USB cable |11.2mm width inferred from photo;11.5×6.5mm shoulder design limit | Height is an assumption; actual fully seated shoulder and unplugging access must fit |
| Wire bends / insulation / tape | Explicit engineering construction envelopes in connected_harness_manifest.json; radial dressing allowances kept separate from physical wires | Flexible wire dressing, battery excess length and≤0.10mm removable restraint tape on stationary lands |
| Foam | Named silicone stock and installed geometry; includes adhesive | Received lot thickness, compression force, closure effort and PCB flatness |

The earlier photographs are evidence of the actual connection arrangement. A photo or STL does not establish every connector dimension, internal wire bend or contact force. Engineering envelopes are intentionally labeled as assumptions instead of claimed measurements.

## Manufacturer references consulted

- [Adafruit battery2011 product page](https://www.adafruit.com/product/2011) — current page notes the2023 taped-sideways cable exit revision.
- [Adafruit-linked pack specification](https://cdn-shop.adafruit.com/datasheets/LiIon2000mAh37V.pdf) — maximum pack envelope and legacy100mm UL1007 leads. Do not treat the legacy free length as the current usable untaped length.
- [JST PH series](https://www.jst-mfg.com/product/pdf/eng/ePH.pdf) — ordinary housings, contacts, wire ranges and installed connector envelope.
- [JST KR-D series](https://www.jst-mfg.com/product/pdf/eng/eKRD.pdf) — transverse-exit compatible connector and specified IDC wire construction.
- [Blue Adafruit SPH0645 microphone](https://www.adafruit.com/product/3421).
- [Same Sky speaker drawing](https://www.sameskydevices.com/product/resource/cms-40504n-l152.pdf).
- [Kingbright LED drawing](https://www.kingbrightusa.com/images/catalog/spec/wp154a4sureqbfzgw.pdf) — physical leads1R,2common cathode,3B,4G; form leads at least3mm from the body.
- [Taoglas antenna drawing](https://www.taoglas.com/datasheets/FXUB63.07.0150C.pdf) — factory adhesive,150mm coax, selected flex dimensions. Recommended metal spacing is not achieved in this compact case; RF testing remains necessary.
- [I-PEX MHF I catalog](https://www.i-pex.com/sites/default/files/downloads/pdf/CATALOG_MHF_I_E.pdf) — mated connector envelope for the retained RF cable.

No unmeasured received-part clearance or physical durability result is recorded as a pass. The print files are a geometry-checked first article built around these documented constructions.