Chalk Ember / raised volume controls

concept 28.2

28.2Experimental branch

The volume controls meet the shoulder line, with matching recesses and supports. A proposed upper-switch terminal form clears the internal guide. Prepared 14 September 2026 in Autodesk Fusion.

Device dimensions

Combined rigid shell envelope · 28.2

Width: 78 millimeters
Height: 150 millimeters
Depth: 24 millimeters

The rim, controls and lens extend beyond the shell. The original shell envelope, guided PTT and antenna cable route are retained.

Download experimental 28.2 · 33.5 MB Read print & assembly guide

One complete set: five editable P1S projects, 26 oriented STL meshes, 95 fabricated-part STEP groups, native Fusion, assembly notes and video. These files belong to the 28.2 experiment.

CAD and offline slicing checks are complete. The proposed lead form, physical fit and inherited antenna/RF checks remain open. This is a fit prototype.

Shared appearance reference. The raised volume-button positions and proposed terminal form are shown in the 28.2 CAD tab.

How the versions relate

28.1 and 28.2 share an earlier source. 28.2 branches from R3.2 A; it does not inherit today’s 28.1 / R3.4 changes.

28 · frozen R3.1

R3.2 A · previously called 28.1

Shared source for both branches

R3.2 A → R3.3 → R3.4

Golden version 28.1

R3.3 battery and USB changes, followed by R3.4 print simplification. Retains the original volume-button positions.

R3.2 A → 28.2

28.2 · Experimental branch

Raises the volume buttons by 17.6 mm, with revised supports and a proposed switch-terminal bend. Physical validation remains open.

R3.2 A → experimental 28.2

Controls at the shoulder line.

01 / Placement and support

A 17.6 mm lift

Volume-up center Y=40.6 mm; volume-down Y=11.6 mm; pitch 29 mm. The upper carrier reaches Y=50 mm, with the metal cap 0.0263 mm below the shoulder line. The front shell, rear shell and flexible rim carry the matching openings.

The upper rim pad moves into the gap at Y=26.1 mm. A local rear-guide relief gives 0.20 mm nominal support clearance, leaving 0.99 mm guide width that needs physical strength and print-tolerance checks.

02 / Terminal clearance

Two proposed lead bends

The two rear terminals on the upper switch turn 90° toward the front, preserving their estimated 3.5 mm developed length. Metal-to-guide clearance is 0.69 mm; the larger solder/insulation envelope clears by 0.29 mm.

The switch model is an estimate. Confirm lead material, length, acceptable forming and electrical operation on the purchased part. CAD clearance does not establish that the actual switch can accept the bend.

79 seconds / narrated CAD walkthrough

See the changes and the checks.

Narrated changes explainer

Walkie_One_28_2_Changes_Explained.mp4

MP4 · 2.8 MB

79 seconds · 1080p · CAD views, measured clearances and open hardware checks.

File checksum

SHA-256: 8f53a9a4f4ddf377a33df02d5ee7ba71585fd89cfc092818d363c2c3b854ae68

concept 28.2

Device dimensions

How the versions relate

Controls at the shoulder line.

A 17.6 mm lift

Two proposed lead bends

See the changes and the checks.

Narrated changes explainer

English captions

Start with the button-fit plate.

01 Button Fit First

02 Shells

03 Internal Retainers

04 Cosmetic Proxies

05 Optical Fit Only

Choose the appropriate material

CAD, meshes and build notes.

Complete 28.2 print and CAD handoff

Illustrated print and assembly guide

Reference assembly · STEP

Native Fusion assembly

Start here

Printer setup and first-fit checks

Assembly and 20-screw checklist

Print-part index

Current fabrication schedule

Terminal form and measured clearances

Open hardware checks

Complete package checksums

P01 Front Shell

P02 Back Shell

P03 Play Button Carrier

P04 Front Switch Clamp

P05 Talk Button Carrier

P06 Volume Up Carrier

P07 Volume Down Carrier

P08 Talk Switch Cradle

P09 Volume Up Switch Cradle

P10 Volume Down Switch Cradle

P11 Speaker Keeper Lower

P12 Speaker Keeper Upper

P13 Microphone Keeper

P14 LED Keeper

P15 Antenna Frame Lower

P16 Antenna Frame Upper

M01 Play Cap PLA Metal Proxy

M02 Volume Up Cap PLA Metal Proxy

M03 Volume Down Cap PLA Metal Proxy

M04 Grille Bezel PLA Metal Proxy

F01 Bumper FLEXIBLE MATERIAL ONLY

F02 Talk Grip FLEXIBLE MATERIAL ONLY

L01 Lens PLA FIT ONLY

L02 Light Guide PLA FIT ONLY

P17 PTT Guide Cap Lower

P18 PTT Guide Cap Upper

All 95 fabricated-part STEP groups

C28 R1 Bezel Plan 48x50

C28 R1 Grille Perimeter Bond

C28 R1 Mesh 45x47 R10

C28 R1 Mesh Edge Bond

C28 R1 Play Symbol Laser Artwork

C28 R1 Scrim 44 8x46 8 R9 9

C28 R1 Scrim Perimeter Bond

C28 R3 Front Contact D5

C28 R3 Front Seat Ring 10x10 Inner8x6

C28 R3 Front Stop 1p8x3p0

C28 R3 PTT Stop 1p6x2p1

C28 R3 Side Contact 2p4x2p2

C28 R3 Side Seat Shim 4p8x5p6

C28 R3 Volume Stop 1p6x1p7

Estimated Upper Switch Formed Terminal Reference

Upper Terminal Solder Insulation Envelope

STEP, mesh and slice verification

Print geometry and orientation manifest

Cradle-lip toolpath check

Saved Fusion reopen verification

What the first build needs to verify.