Walkie One Concept 5.2  |  Revision R5  |  Prototype DFM  |  1
Walkie One Concept 5.2
Revision R5 Manufacturing Handoff
4 September 2026  |  Prepared for Jacob Catalano and Rapid Product Solutions
Please quote one complete prototype enclosure set for the Rubber Bumper and Rigid Core Lozenge 
concept. The nominal body is 88 mm wide, 136 mm tall and 27.2 mm deep. Use the enclosed STEP 
assembly for nominal geometry and the part-level bill of materials for manufacturing processes.
This package is ready for quotation, manufacturing review and a physical fit prototype. Release the finished 
material build after checking the actual electronics, button travel, cable insertion and material samples. The 
CAD has not been physically assembled or qualified for production.
R5 changes: a centered 1.8 mm microphone aperture sits directly between the light and play key. Its 
breakout and the concealed light guide are repositioned inside the existing shell. WALKIE ONE and 
Designed in Los Angeles are centered on the back in two muted warm-gray tones. The raised play key and 
27.2 mm body depth are retained.
USB alignment remains open: R5 retains the board-mounted charging port at Z-4.740, 4.74 mm behind the 
volume-button centerline. A centered socket requires a separate internal connection with verified fit. This 
relocation is not included in the enclosed CAD.
Design intent: an ivory rubberlike perimeter around exposed hard panels, a perforated speaker face, an 
orange PTT paddle, sage volume controls and a circular aluminum play key. CAD color values indicate 
visual targets; physical samples control the finish.

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Website inspiration and front details
These are the original Walkie One website images for concept 05.2, the Lozenge version of Rubber Bumper 
+ Rigid Core. They establish the intended appearance and feel. They are concept artwork rather than 
photographs of the R5 prototype or dimensioned manufacturing views.
 
 
Website view 1   |   Website view 2 front right   |   Website view 6 front left
The reference combines a warm ivory perimeter, an exposed hard center, a broad perforated speaker panel 
and a round play key. The orange side paddle and sage volume controls distinguish the interaction zones. 
Preserve the soft rounding and restrained contrast when matching physical finish samples.
Reference feature
Meaning for the prototype
Soft perimeter
Cast urethane bumper with a fine matte finish around the rigid structure.
Speaker and play surfaces
Hard satin panel and a concave aluminum play key; use the R5 STEP for the 
exact perforations and control geometry.
Color and texture
Website artwork communicates appearance. Use approved physical samples to 
select pigment, texture and gloss.
Image source Walkie One concept gallery

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Website inspiration from the sides and rear
The remaining three website views explain the wraparound shape, side controls and rear panel treatment. 
They belong to the same 05.2 reference; differences between the concept views are illustrative rather than 
dimensional instructions.
 
 
Website view 3 right   |   Website view 4 rear   |   Website view 5 left
The broad back panel and continuous perimeter inform the R5 shell. R5 uses a removable rear cover with 
four countersunk screws so the electronics can be serviced.
The reference shows a rear USB opening. R5 provides right-side USB access aligned with the supplied PCB 
connector. A rear-facing port would require a separate extension assembly, which is not part of the supplied 
hardware or this CAD package.
The website renders fine texture on the side controls. R5 defines the key and grip-pad shape; physical 
texture and coating samples must be agreed with Rapid Product Solutions.
Image source Walkie One concept gallery

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From concept reference to the R5 design
Compare the visual reference with the current enclosure geometry. The website image is on the left and the 
R5 CAD preview is on the right. Image scale and perspective are illustrative; STEP geometry and the 
dimension table govern manufacture.
 
Website inspiration 05.2   |   Current R5 CAD
Feature
Current R5 decision
Play key and status light
Raised 34 mm play key at X0 Y-38. The 5 mm light is directly above it at X0 Y-13 
via a clear guide.
Body and materials
88 x 136 x 27.2 mm. Retains the rounded lozenge, soft perimeter, hard center and 
the specified material families.
Hardware driven details
Right-side USB passage, service screws and internal mounts follow the supplied 
components.
R5 places the microphone aperture on the front centerline between the light and play key, and centers the 
rear artwork in two muted warm-gray tones. The 27.2 mm silhouette, play key, speaker and battery positions 
are retained.

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Current CAD front and rear
The front view below is captured from the R5 Autodesk Fusion assembly. The rear view is rendered from the 
same exported enclosure solids and supplied print artwork. Purchased components visible through openings 
are references, and their CAD display colors do not specify their finish.
 
R5 front in Autodesk Fusion   |   R5 rear shell
View
Inspect these features
Front
Centered LED above the raised circular play key, perforated hard panel and separate 
microphone aperture.
Rear
Centered WALKIE ONE wordmark with Designed in Los Angeles directly below, four screw 
openings, removable hard cover and separate soft bumper.
Nominal envelope
88 mm body width and 136 mm height; 27.2 mm depth. The side keys extend the measured 
overall width to about 89.16 mm.
The CAD views show nominal geometry. See the mechanical reference drawing and STEP files for 
dimensions rather than measuring the images.

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Current model from four angles
These views show the R5 enclosure and rear print artwork directly from the CAD exports. The centered 
wordmark and smaller inscription below it use a subdued tonal finish on the broad rear panel. Colors are 
display targets; the actual prototype finishes require approved samples.
 
Front left   |   Front right
 
Rear left   |   Rear right
The shell remains 88 x 136 x 27.2 mm. Side controls, front proportions and rear screw access are retained.

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Current CAD side profiles
These orthographic views show the two interaction sides of the R5 case. The case depth remains 27.2 mm 
and the main face proportions are unchanged from the centered-light revision.
 
Left side orange PTT paddle   |   Right side volume keys and USB
Feature
Nominal detail
PTT paddle
58 mm long, center Y10. A cast grip pad bonds to the rigid captured key core.
Volume keys
19 mm high, centers Y30 and Y5; sage grip pads over rigid key cores.
USB opening
15 mm Y by 10 mm Z; 17 x 12 mm mouth. R5 center Z-4.740 remains 4.74 mm behind 
the volume keys at Z0. Centered USB is pending; verify actual cable insertion.

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Current model from above and below
Top and bottom CAD views show the unchanged rounded edge profile and narrow depth. The print 
treatment adds no rigid badge or raised feature. The rear seam remains openable for service.
Top view
Bottom view
The exterior body depth is 27.2 mm. The status guide face stays inside the bumper envelope. Use the STEP 
geometry for toolpaths and fit dimensions.

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Centered light and raised play key
This enlarged R5 CAD view shows the requested control arrangement. The small dark aperture on the 
centerline between the light and play key is the relocated microphone port. The amber CAD color identifies 
the RGB indicator location; it is not a fixed electrical operating color.
R5 control detail rendered from the exported solids
Control relationship
Nominal value
Shared horizontal center
Play key X0; light X0; microphone X0.
Vertical spacing
Light Y-13; microphone Y-18.25; play key Y-38. The 1.8 mm mic aperture 
has 1.85 mm clear space to each adjacent visible edge.
Key clearance to lower panel edge
The visible key ends at Y-55, 6 mm above the hard center panel bottom at 
Y-61.

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Optical guide and internal clearance
The visible light stays at (0,-13). To fit the microphone between it and the play key, R5 moves the internal 
LED to (14,-19), base Z2.9, and links it to the visible output with a concealed clear PMMA bridge. The actual 
microphone breakout is centered at (0,-17.488,9.8).
R5 internal plan and centerline section through the microphone
The light is midway between the grille edge Y-5 and play-key edge Y-21. The microphone center Y-18.25 is 
midway across the 5.5 mm light-to-key edge gap. The former left-side front aperture is filled.
The guide spans 15.23 mm in plan, with a 2.8 x 1.3 mm bridge. The retainer has a nominal 0.2 mm bond 
gap. Local front-wall roofs are 0.85 mm above the guide and 0.8 mm above the microphone gasket. Inspect 
these areas after finishing.
Prototype checks: confirm guide machining, brightness, RGB mixing, light leakage, adhesive retention and 
LED lead routing. Do not assume optical performance from the geometric fit check.

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Rear identity and print placement
Use only the WALKIE ONE wordmark, without the separate W symbol. Center the complete two-line block 
on the rear panel. Center Designed in Los Angeles directly below the wordmark in IBM Plex Sans Regular. 
Both lines are upright when viewed from the rear.
R5 rear print placement on the actual enclosure model
Wordmark: 36 mm wide, center X0 Y2.96. Inscription: 28 mm wide, center X0 Y-4.04. The two lines share 
the horizontal center and have approximately 3.4 mm of clear space between them. Registration target 
+/-0.5 mm; size target +/-0.2 mm. The supplied SVGs contain the production artwork at actual size.
UV print with nonconductive ink on the finished rigid PA cover. Use two subdued warm-gray tones: WALKIE 
#948D80; ONE and the inscription #AAA293. These screen values are targets; approve ink swatches on the 
finished panel. Approve an actual-size sample for letter clarity, adhesion and rub resistance. CAD print 
meshes are visual references only and must not be fabricated as separate parts.
Approved artwork source Walkie One design system

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Internal hardware placement
The front tub, front bumper and grille are hidden in this Fusion view so the purchased hardware and its 
supports can be seen. The long flexible lead routes are omitted from the placed packaging references and 
require a physical wiring trial.
R5 internal arrangement in Autodesk Fusion
At the top, the speaker sits at Y43.5 with its mounting ears along X. The battery sits below it at Y5. Their 
rigid-body gap is 0.5 mm nominal. The microphone is now on the front centerline, with the underlying LED 
offset to its right; the 27.2 mm body depth is retained.
The main PCB and rear antenna occupy deeper layers. The play-switch holder and microphone cradle 
occupy the lower front area. CAD reference colors distinguish objects and are not manufacturing material 
assignments.
Check the actual speaker seal, battery wrap, connector overmolds, wiring and PCB edge contacts before 
committing to the finished material build.

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Exploded enclosure assembly
This Fusion exploded view separates the front and rear skins, rigid covers, grille, play key and side controls. 
Separation distances are for explanation only. The STEP assembly contains the parts in their installed 
positions.
R5 exploded assembly in Autodesk Fusion
The bill of materials specifies 27 fabricated parts: 15 SLS nylon parts, 8 cast urethane parts, 1 CNC 
aluminum play key, 1 clear PMMA guide and 2 cut silicone foam gaskets. Rear printing is a finish operation; 
its CAD references are excluded from fabrication. The ten purchased-hardware references are excluded 
from the fabrication order.
Assemble and trial-fit the control mechanisms and acoustic seals before bonding the internal supports. 
Install the PCB, battery and antenna, route the wiring, then close the rear cover with the four screws. The 
detailed assembly sequence follows the material specifications.

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Dimensions and thin packaging
All CAD exports use millimetres. X is width, Y is height and positive Z points toward the front face. The origin 
is the center of the nominal body. The Concept 5.2 Revision R5 mechanical drawings in docs show front and 
right elevations and hardware placement.
Feature
Nominal value
Body and measured fabricated 
envelope
88 x 136 x 27.2 mm; including side keys about 89.16 x 136.00 x 27.20 mm
Main structure and perimeter
2.0 mm front/rear walls; 2.4 mm side walls; 1.2 mm nominal side bumper; locally 
recessed edge seats
Body rounding and closure
R26 plan corners; R5 face edges; rear seam 0.3 mm
Play key and indicator
34 mm key at (0,-38); 5 mm light output at (0,-13), face Z13.4; 5.5 mm clear to 
grille and play key
Speaker face
62 x 66 mm, R22; 473 through holes, diameter 1.6, hex pitch 2.6
Controls and microphone
PTT Y10, 58 mm long; volume Y30 and Y5, 19 mm high; mic aperture (0,-18.25), 
diameter 1.8
USB access
Right-side passage 15 mm along Y x 10 mm along Z; center Y-32.139, Z-4.740; 
flared mouth 17 x 12
Rear artwork
Wordmark width 36 mm, center (0,2.96); inscription width 28 mm, center (0,-
4.04). Read upright from rear.
Rear fasteners
4 x M2.5 x 10 countersunk screws; centers X +/-34, Y-44 and Y46; 90 degree 
seat, diameter 5.0
What sets the depth
The populated board occupies Z-9.3 to Z0.2. Above it, a 0.5 mm gap, 0.8 mm battery tray and 0.2 mm pad 
put the battery at Z1.7. Its supplied protection detail reaches Z10.1, leaving 1.1 mm to the front inner face at 
Z11.2. The 2.0 mm front wall ends at Z13.2 and the bumper lip reaches Z13.6.
At the rear, the 2.0 mm wall, 0.8 mm antenna seat, nominal 0.1 mm bond line, antenna body/feed and 0.65 
mm gap to the board fill the opposite side of the stack. The battery center is Y5. The speaker center is 
Y43.5, with ears along X and body Z5.4 to Z10.4. This yields a compact 27.2 mm candidate for these parts 
and allowances; it is not a proven absolute minimum.
The battery allowance must be checked against the physical pack and its supplier swelling guidance. 
Reserve the remaining cavities for insulated leads and connectors; cable routing is not represented by a 
validated sweep.

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Materials and manufacturing processes
Manufacture the parts by the processes below. The names RPS Nylon PA and RPS Elastomer refer to 
Rapid Product Solutions published material families. Please put the current manufacturer, resin or powder 
grade, hardness, finish and lot traceability on the quotation. Do not change material families without a 
reviewed sample.
Part group
Qty
Material and process
01, 02, 05, 07, 09, three 10 keys, three 12 
cradles, 15, 16, 17, 19
15
RPS Nylon PA, SLS. Finish visible panels to a smooth satin 
champagne/ivory target. Finish guide and screw features after 
printing.
03 and 04 perimeter bumpers
2
RPS Elastomer cast polyurethane, 40 +/-5 Shore A. Ivory 
pigmentation; fine matte texture. Cast from finished masters.
Three 11 collars and three 21 grip pads
6
Same RPS Elastomer. Ivory collars, orange PTT pad, sage 
volume pads. Bond to the structural supports and key cores.
13 circular play key
1
6061-T6 aluminum, CNC. Bead blast and clear anodize; 
preserve the play glyph and running clearance.
08 speaker gasket
1
Closed-cell silicone foam, 1.5 mm free thickness, 1.2 mm 
installed. Cut annulus: outside 39.6, inside 36.4 mm.
18 microphone gasket
1
Closed-cell silicone foam, 2.0 mm free, 1.57 mm installed 
(21.5% compression). Rounded rectangle 4 x 3 mm, R0.4; 
centered 1.8 mm hole. Confirm seal and compression force.
27 offset status light guide
1
Optical-clear PMMA acrylic, CNC and optical polish; lightly 
diffuse output. Keep clear; amber in CAD denotes illumination. 
Approve optical performance and tooling feasibility.
Rear logo and inscription
AR
UV print on the finished PA rear panel using the supplied 
artwork. Nonconductive ink. Qualify adhesion, rub resistance 
and letter clarity.
Assembly consumables (as required)
AR
4 stainless M2.5 x 10 countersunk screws; 2 nonconductive PET 
battery straps; insulating pads and compatible adhesive system.
Color targets: ivory #EDE5D5, hard panels/play key #C6BEAD, orange #BE754E and sage #839078. 
Screen colors are not color standards. Approve physical plaques for color, texture, grip and gloss before 
finishing the full set.
RPS should choose primers, adhesive chemistry, bond thickness and cure for the actual nylon and cast 
urethane grades. Confirm cast shrink compensation, parting lines, gates and vents. The supplied geometry 
is a prototype assembly, not mold tooling.
The manufacturing/SLS_NYLON folder contains only nylon geometry. CNC_CLEAR_PMMA contains the 
clear guide. Elastomer files are casting geometry; aluminum files are machining geometry; foam files are 
cut-pattern envelopes. Printing every STL in one rigid material will not reproduce the intended case.

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Assembly and critical fits
1. Prepare the rigid parts. Deburr the SLS parts and clear every grille aperture. Trial-fit the uncoated parts. 
Target +/-0.20 mm general dimensions and +/-0.10 mm finished moving fits, subject to RPS agreement. 
Include coating thickness in the finished fit.
2. Fit the controls. Insert the PTT and volume key cores from inside the front tub, followed by their switch 
cradles. Bond each grip pad to its core and its collar to the bumper. Keep adhesive out of guides. Fit the 
circular play key from the rear before installing its switch holder. Preserve the relief around the moving play 
flange; the microphone support now occupies the gap above it.
3. Set switch travel. Position the three B3F-3150 switches and one B3F-4000 switch with about 0.2 mm 
actuator freeplay. Geometric inward travel is 0.8 mm at side keys and 0.75 mm at the play key. Adjust shims 
or compliant stops to the measured switch lot. Verify electrical actuation, return and safe overtravel before 
bonding the cradles.
4. Install audio and light. Fit the speaker with ears along X in the upper cradle. Seat its 1.2 mm installed 
gasket against the frame and the hidden upper grille sealing land. Bond the cradle tabs with a 0.2 mm bond 
line. Fit the microphone breakout at (0,-17.488,9.8), facing its sealed front duct at (0,-18.25). Install the RGB 
LED at (14,-19), base Z2.9. Fit the clear guide and its retainer so the visible output is at Y-13. Bond at the 
support lands with a nominal 0.2 mm gap, keep the optical path clean and mask pocket walls with opaque 
nonconductive coating. Retain the microphone with a 0.2 mm support pad.
5. Locate the PCB and battery. Seat the actual 1.33 mm PCB substrate at Z-7.215 to Z-5.885. Four tabs 
contact only the outer 0.6 mm of the board edge. Insulating compliant pads occupy the 0.2 mm gaps on 
each face. Check contact lands physically before closure; do not bend the board or clamp components. 
Bond the battery tray feet to their seats, add a 0.2 mm pad and secure the cell with removable PET straps 
through the slots without compression preload.
6. Route and secure wiring. Route the supplied battery, speaker and antenna leads through the remaining 
cavities, provide strain relief and insulate terminations. Keep wires clear of the screw towers, moving 
controls and speaker diaphragm. Fit the antenna to the rear polymer seat; the 150 mm coax route remains a 
physical assembly task.
7. Close and test. UV print the rear artwork at the specified centers and approve a full-size sample. Bond 
front and rear bumpers separately, keeping the rear seam free. Close with four M2.5 x 10 countersunk 
screws; confirm approximately 5.3 mm engagement and no bottoming. Trial-fit the actual USB cable through 
the recessed right-side passage. Check light brightness, RGB mixing and leakage, charging access, 
record/playback, every control and cellular reception.
The right-side port follows the supplied board at Z-4.740. The requested alignment with the volume buttons 
at Z0 remains open. Moving the board forward by 4.74 mm interferes with the battery tray; select and verify 
a separate socket and internal connection before revising the enclosure. R5 contains no USB extension 
assembly.

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Verification and release checks
The validation files report nominal geometry checks. They do not establish physical assembly, material 
strength, RF performance or acoustic performance. Read the release items below before committing to the 
finished prototype.
Check
Evidence
Enclosure parts
27 individual parts. All are single valid solids with watertight STL meshes.
Static fabricated parts
0 reported intersections above 0.005 mm3.
Purchased hardware against 
case
0 reported overlaps above 0.02 mm3; original PCB BReps and conservative hulls 
of disconnected mesh pieces.
Hardware against hardware
0 reported overlaps above 0.02 mm3 using the same method.
Button movement
0 reported fabricated-part clashes across sampled inward positions. Electrical 
switch travel requires physical verification.
Microphone and moving play key
No clashes above 0.005 mm3 at five inward travel samples up to 0.75 mm, using 
source microphone geometry.
Native Fusion archive
Exported and reopened successfully.
Fusion STEP round trip
27 of 27 parts passed solid validity, bounds and volume/solid-difference checks.
The STEP checks compare solid validity, analytic bounds and volume. If volume differs by more than 0.1 
mm3, the check also requires a relative difference below 0.01% and no residual above 0.005 mm3 in either 
direction of solid subtraction. See fusion_roundtrip_validation.json.

Confirm the source components, solder joints and connector overmolds. Check the 0.5 mm nominal 
battery-to-speaker gap and the raised speaker seal and lead direction.

Check the 27.2 mm stack with real wiring and the battery swelling allowance. Confirm the four narrow 
PCB edge contacts remain on bare substrate under tolerance and assembly loads.

Measure the chosen switch lot and set stops accordingly. Omron specifies pretravel variation; nominal 
CAD spacing alone does not qualify actuation or life.

Approve the current nylon and urethane grades, PMMA optical grade, silicone foam sheets, adhesive 
system, print ink and physical finish samples. Test the new guide for brightness, RGB mixing, leakage 
and retention.

Test cellular reception with the rear antenna installed close to electronics. The CAD antenna location 
has not been RF tuned.

Test microphone isolation, speaker leakage, sound quality, thermal behavior and charging access. No 
ingress, drop, flame or regulatory rating is assigned to this enclosure.

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Files and source references
Start with step/Walkie_One_5_2_R5_CASE_ONLY.step. It contains the fabricated enclosure parts in their 
assembled positions. The Fusion archive contains the case plus separate purchased-hardware references. 
Keep every REF item out of the manufacturing order.
Location
Use
fusion/Walkie_One_5_2_R5.f3d
Editable native Fusion direct BRep assembly, with named part and 
process metadata. No feature-driven parametric timeline is claimed.
step/parts and stl
Individual enclosure parts in assembly coordinates. STEP is the nominal 
geometry authority; STL units are mm.
manufacturing
Process-sorted geometry for SLS, casting, CNC and foam cutting. 
Includes DXF speaker-ring and rounded microphone-gasket cut outlines.
docs
Concept 5.2 Revision R5 handoff, mechanical drawings and BOM, plus 
source hashes and geometric verification reports.
references and source_inputs
Ten placed purchased-component references plus all eight original 
supplied files, preserved byte-for-byte.
artwork and inspiration
Approved logo SVG, outlined rear print files, three print-reference 
groups, all six concept images.
code
R5 update source and Fusion assembly/export scripts. The five prior 
CAD solids used by apply_r5.py are isolated in source_baseline_R4; 
they are not current fabrication files.
The supplied battery, speaker and antenna meshes include long straight leads. The placed packaging 
references retain their rigid body details and antenna feed tab; the complete straight leads remain in the 
originals. Final cable routes, bend radii and connectors are not validated. The supplied LED mesh contains 
non-watertight and duplicate planar fragments; it is retained as reference geometry and is not a print part.
Sources reviewed 4 September 2026. RPS material sheets are dated 2019 and remain linked from its 
current materials page; current grades must be confirmed on the quote.
Walkie One approved logo and design guidelines
Walkie One concept 05.2 and shape definition
Rapid Product Solutions SLS service and materials
RPS urethane material sheet including 40 +/-5 Shore A elastomer
RPS urethane casting process and finishes
Adafruit 2011 battery dimensions
Same Sky CMS-40504N-L152 mechanical drawing
Omron B3F dimensions and pretravel tolerances
Taoglas FXUB63 flex antenna
