# First-article assembly and process plan

This is an inspection plan, not validated manufacturing instructions. Use the dated native-position files together. Do not use the stale original rear-shell STL for the updated design.

1. Resolve front-shell/frame integration, acoustic-film trim and flexible rim compression. Agree rigid, flexible and clear processes with the shop. Material grades, hardness, orientation, shrink allowance, layer settings, torque and finish are not qualified here.
2. Inspect received parts and distinguish slicer supports from permanent CAD features. Record actual dimensions, pilots and process settings. No G-code is supplied.
3. Dry-fit the whole PCB and a faithful battery dummy. Native laminate/shell overlaps have cleared, but a 0.114 mm3 resistor/rear-shell contact and 40.761 mm3 battery/rear-shell overlap remain. Do not bow the board or compress a pouch to close the case.
4. Check the play cap through its full travel. Its static front-shell overlap has cleared; this does not prove actuation or return. The play-switch base still intersects the nominal switch by 10.800 mm3. Confirm the received switch before correcting its seat. Check side controls and talk ends.
5. Fit speaker/film, microphone/seal, LED housing and the two optics. Optical static clearance is not proof of brightness or uniformity. LED-housing wire/hardware contacts remain open.
6. Reconcile the hardware and wiring now visible in the source against actual components. Verify fastener lengths, engagement, bottoming and tool access. Prepare harnesses only from the authoritative PCB schematic and connector pin map, never CAD display colours.
7. Install all intended connections with natural bends, insulation and slack. Retain factory battery and RF cables intact. Inspect coax, control leads, LED leads and battery/speaker routes. Existing contacts are not a connected-fit pass.
8. Trial-close by hand before fastening; check rim fit in the specified material. Do not use screws to pull a conflicting stack together. Confirm actual USB insertion and all control returns.
9. Complete Physical_Qualification_Log.csv. Any subsequent geometry change requires a new dated export set.