R3.1 aligned light · 0.4 mm nozzle · PLA · full size
# Walkie One 28 R3.1 — Bambu P1S / 0.4 mm / PLA **Start with `Bambu_Studio_Projects/01_Button_Fit_First_P1S_04_PLA.3mf`.** Open as a project, not “geometry only.” This ZIP contains the latest aligned-light revision, at full size: rigid shell envelope 78 × 150 × 24 mm. No scaling or enclosure geometry changes were made for this package. This is a mechanical fit prototype. The files have been checked and sliced offline; no physical print or assembly has been tested. The switch dimensions remain estimates beyond their listed nominal sizes. ## How to print 1. Unzip the entire folder. Open one numbered `.3mf` in Bambu Studio as a project. 2. Confirm **Bambu Lab P1S, 0.4 mm nozzle, PLA**, and select your actual PLA preset. Projects use Generic PLA as a starting point. Confirm your actual build plate; these projects default to Textured PEI. Match the spool/AMS slot to the chosen filament. 3. Keep scale at **100%**. The STLs are in millimeters, individually oriented and placed at Z=0. Keep the supplied orientations; the shells have their outer faces down and interiors up. 4. Use **Slice plate** and inspect the Preview. Supports are enabled, including supports that start on a part. Remove support from the button passages, screw pilots, shell edges and LED area carefully. Do not mistake removable support for a CAD feature. 5. Print Plate 01 first. Trial the actual switches in the cradles and front clamp. Then print the shells and retainers. Avoid gluing cosmetic parts until the moving controls have been checked. The projects are editable and deliberately contain no pre-generated G-code. They were validated with Bambu Studio 2.7.1.62. No printer job was submitted. ## Plates and quantities Every part appears once; the numbered plates together supply one rigid prototype set. Print additional copies of the tiny cradles if desired. | Plate | Contents | Estimated time | Estimated PLA | |---|---|---:|---:| | 01_Button_Fit_First | 8 pieces: four carriers, three side-switch cradles, front clamp | 43 min | 4.62 g | | 02_Shells | Front and back shell | 6 h 26 min | 73.44 g | | 03_Internal_Retainers | 6 pieces: speaker ×2, microphone, LED, antenna frames ×2 | 26 min | 2.65 g | | 04_Cosmetic_Proxies | 4 optional PLA stand-ins for metal play cap, volume caps and grille bezel | 16 min | 1.68 g | | 05_Optical_Fit_Only | 2 optional fit gauges: lens and right-angle light guide | 10 min | 0.29 g | Times and material are slicer estimates including support/brims; actual calibration, purge and spool requirements can differ. The first three plates total about **7 h 35 min and 81 g**. ## Included settings 0.12 mm layers, 0.16 mm first layer, Arachne walls, 4 wall loops, 5 top/bottom layers, 25% gyroid infill, outer wall 40 mm/s, 3 mm outer brim, automatic snug supports, 0.16 mm support Z gap. PLA can leave marks on supported surfaces. The shell faces take the build plate texture; this print will not reproduce a cast cosmetic finish. ## What PLA does and does not replace - **P01–P16:** rigid mechanical fit parts. The internal design originally targeted other prototype materials; PLA strength, creep and fastening durability are not qualified. - **M01–M04:** optional PLA shape/fit stand-ins for metal caps and the grille bezel. They do not reproduce the weight, stiffness or finish of metal. - **L01–L02:** opaque PLA fit gauges only. They cannot verify illumination. Use the clear optical parts and coupling film described in `Documentation/Light_Assembly_Notes.md` for a working indicator. - **F01–F02:** original bumper and orange talk-grip meshes are in `STL/Optional_Flexible_STL`. They need a flexible material/process and are deliberately excluded from the PLA projects. Do not force a rigid PLA bumper over the case. The talk carrier can be inspected without its soft grip. A later TPU trial needs a TPU profile; normal TPU 95A should use the external spool rather than ordinary AMS routing. TPU is not automatically equivalent to the specified cast elastomer. - **Speaker grille:** cut/sourced woven metal mesh, not the 92 reference wires in the CAD. No nonprintable wire model is in the STL set. The mesh and adhesive/scrim cut outlines are included in `Cut_Stock_DXF`. - **Shims, pads, gaskets and bond films:** use measured sheet/foam/adhesive stock. Their modeled thicknesses include adhesive and, for compressed pads, describe installed thickness. Do not replace them with rigid PLA or stack all alternative shims together. - **Screws, switches and electronics:** purchased parts, not printed parts. See the assembly checklist. ## First fit checks - The volume cradles contain a **0.40 mm retaining lip**. Both lips are represented in the verified 0.4 mm nozzle toolpaths, but are delicate. Inspect them after support removal; reject cracked or missing lips. - Check the nominal **0.15 mm button rest gap** by hand with real switches. It is not an achievable-printer-tolerance claim. Confirm each button returns freely, is not held electrically on, and does not overdrive the switch. - Check screw-pilot diameters and blind depths before fastening. These are pilot holes, not modeled helical threads. Establish the appropriate tapping/fastening method on a spare feature and use the listed screw sizes; do not force a machine screw into undersized PLA or substitute a longer screw. - Check the PCB, battery, wiring and U6 clearance with actual parts. U6 remains a nominal placeholder, and final populated-module height is unverified. Verify LED output and cellular RF performance separately. Do not close the enclosure by compressing a battery or forcing a PCB. Use `Documentation/Assembly_and_Nonprinted_Parts.md` for the hardware list and sequence; `Documentation/Part_Index.md` maps every printed filename to its Fusion component. `Reference_STEP_NOT_FOR_SLICER` contains individual current fabricated-part references at their assembly coordinates. Do not load that entire folder as a print job. ## Printer sources [Bambu P1S specifications](https://ca.store.bambulab.com/products/p1s) and the bundled Bambu Studio 2.7.1.62 P1S/Generic PLA presets informed the printer setup. [Bambu Studio profiles](https://github.com/bambulab/BambuStudio/tree/master/resources/profiles/BBL). Printer compatibility and a successful slice do not establish physical fit.