# Supplier documentation update - 6 September 2026

Replaced the first-read handoff with a concise Rapid Product Solutions brief; retained technical detail separately; clarified quote stages, material capability, responsibilities and missing inputs; added BOM scope routing and refreshed delivery hashes. CAD and physical-test status are unchanged.

## Earlier CAD change record

# Concept 5.2 / R5 to R6 / 2026-09-06

## Geometry

| Part | Change | Purpose |
| --- | --- | --- |
| 05 grille | Rear 57.1 x 61.1 x 0.15 mm mesh recess | Uniform black breathable backing; visible R5 hole field unchanged |
| 15 play holder | Switch seat lowered from Z3.70 to Z3.50 | Room for measured paired PET shims |
| 16 LED support | Flange seat lowered 0.75 mm; upper retainer preserved | Flat optical input, existing LED retained |
| 18 microphone foam | Installed foam 1.57 to 1.43 mm; original footprint/bore | Counts the real 0.14 mm PSA separately without changing roof or microphone |
| 27 PMMA guide | Removed inlet counterbore; uniform 1.3 mm underside | Removes 0.45 mm local optical cap and improves 3-axis machining access |
| 28 / 29 | Acoustic mesh envelope / microphone PSA | Explicit installed material budgets |
| 30 x2 | 0.30 x 0.80 x 0.20 mm installed foam pads at end-pad edges | Captive support outside 5 mm optical apertures |
| 31 x2 / 32 | Play seat shim pair / stop ring | Independent freeplay and post-contact calibration |

Original LED rigidly moves Z-0.75; original play switch nominal reference moves Z+0.08 for the illustrated calibration. All source purchased files are unchanged and unscaled. Twenty-two of the original 27 fabrication shapes are geometrically unchanged. All four exterior shell/bumper shapes and visible grille geometry are unchanged.

## Manufacturing and appearance

Light champagne dyed anodize replaces the clear-anodize/champagne ambiguity. Nylon and PU have separate surface preparation, coating/texture, color-master and masking definitions. Concealed grille-land faces get a matte nonconductive black treatment; no metal grille is substituted. Added full-process grille crop, hole witness, PMMA nest, microphone locator, screw coupon, cable gauge, exact sheet-cut DXFs and full-front appearance sample assembly.

Rear wordmark and inscription artwork are byte-preserved. P1/U1/K1/O1/M1 physical approval is pending. R6 renders show proposed finishes; they do not reproduce a measured physical master.

## Engineering evidence

Added finished fit budgets, explicit microphone foam/PSA compression calculation, measured switch-seat/stop calibration, screw-head selection and sample torque procedure, actual cable SKU cross-section gauge and a conservative speaker-to-cell budget. Added separate ALT1 direct-emitter optical geometry as a contingency requiring custom flex/electrical work.

## Unclosed physical items

Actual resin/powder/mesh grade and full finish samples; optical efficiency, mixing, leakage and retention; seal cutability and speaker-on isolation; control force/return/overtravel and life; screw torque and finish survival; cable reach and all real wire/tab/insulation envelopes; battery supplier swelling/thermal/retention requirements; final RF and durability. These remain evidence gates, not claimed passes.