Experimental prototype / Chalk Ember
Original exterior. Stronger internals.
A holistic durability redesign, from the battery and buttons to the smallest retainers, supports and wiring details.
Print-test candidate · Physical review pending. This is a Future Exploration. Golden remains 28.1 / R3.4. Promotion will be decided after reviewing the printed build.
Original bare case dimensions. Bumper contour, button shapes and protrusions, openings, grille and seam are preserved.
24 rigid parts, 2 flexible-only parts and 2 optical fit proxies. Millimetres; print at 100% scale. Use the material notes and process coupons.
Original AI-generated Chalk Ember appearance reference. The CAD tab shows the revised 28.4 print geometry, including polymer controls.
One build, two identifiers. Version 28.4 is the public name for engineering build 28.1 / R3.6, derived from the original 28.1 / R3.4 package. The CAD filenames, review and video keep their original engineering identifiers. Publication changes the name, not the geometry.
A matched set for the first physical review.
Use the hardware, soft-stock and fastening schedules together. The complete package includes the annotated component review, all 133 risk entries, diagrams and adapter fabrication instructions.
Start with representative coupons using the intended material, orientation and finishing. Rigid, flexible and optical parts are separated in the STL ZIP. Orient and slice individual meshes; no printer profiles or G-code are supplied.
Measure the battery, switches, populated PCB, screw heads and installed pads. Test closure by hand. Never use screws to pull an interference together or force the pouch past a keeper.
Keep the bumper off. Fit antenna clamps before the battery, volume captures before the adjacent J9 common wire, and battery keepers before dressing factory lead 2. Install the bumper last.
START_HERE_28_4.md
MD · 2 KB
SHA-256: d3f58cfca9146b77a52f2045801f37611be0f1f93ac322b127bc7ddff02dce9dWalkie_One_R3_6_Durability_Review.pdf
PDF · 2.7 MB
SHA-256: 89395d665526612b4fa0445ae72ea3c4be867b3a96b947d9a999c2d1931fb350Walkie_One_28_4_Process_Coupons.zip
ZIP · 1.2 MB
STEP/STL coupons and protocols. Match product material, process and critical-feature orientation.
SHA-256: b5d9354397ef848c4bf5c96f90d71e2756816efe69ea57ca2a67cf7f9f5a4595The full reference assembly contains electronics, hardware, wiring, stock and gauges. Use it to inspect assembly; send individual print parts to your slicer. The factory battery lead, plug, protection and tape remain intact.
25 original parts reviewed · 3 added retainers · 32 screws · 133 feature risk entries.
Battery
A 62.6 × 39.1 mm bare cavity accommodates the agreed 62 × 38.5 × 8.5 mm maximum battery body with documented clearance. Low rounded locators and removable bridges replace insertion past fragile walls. Measure the dressed battery and stock; do not preload the pouch.
Volume controls
Visible button shapes and positions stay fixed. Broader internal stems, capture flanges and blended roots replace the thin legs. Independent removable keepers capture the buttons without bending printed features during assembly.
PTT and play
The long printed PTT rods give way to broad guided sliders, end guides and a central stop. Play capture sections and shell stops are reinforced. Revised switch cradles and guides carry operating loads through supported surfaces.
Small retainers
Speaker-keeper edge material increases from approximately 0.24 mm at the original countersinks to 1.5 mm. Broader microphone and LED seats, coordinated head styles and fastening clearances reduce splitting and component loading.
Shells, PCB and antenna
Both shells, all eight PCB support roots, support pads, antenna clamps and nearby clearances are reviewed together. Connector forces and cable pulls have defined support and restraint. The original enclosure still limits antenna-to-metal spacing.
Wiring and stock
A removable passive adapter keeps the battery’s factory lead, plug, protection and tape intact. Its carrier, cover, wiring, isolated nets, pads and screw access are specified. Flexible parts, optics, adhesive and seals have explicit installation and test requirements.
4 min 22 sec · Narrated CAD walkthrough · English captions.
The narration calls this build 28.1 / R3.6. It is the same CAD published here as Version 28.4. Actual CAD comparisons explain the design rationale and the physical checks still required.
Walkie_One_28_1_R3_6_Changes_Explained.mp4
MP4 · 9.1 MB
Video identifies this same engineering build as 28.1 / R3.6; website name is Version 28.4.
SHA-256: 6bb4ed30f4170bb97faf431160c126ff3d064ffb7a3abf34660092f99963a814Transcript.md
MD · 5 KB
SHA-256: 05e0b571dc2be88041402a3252110e48ed1dc97fd284189fdfed2ca893d85877All 28 released print parts, with rotation, zoom, part selection and an illustrative exploded view. Purchased electronics, grille mesh, screws, wires and stock are in the downloadable full reference CAD. Display colours do not specify a qualified material.
A closer look. A finish that’s yours.
28.4 · R3.6 source finish.
R3.6 engineering · 78 × 150 × 24 mm original bare case. Exploded offsets illustrate the assembly. Materials and colours are screen previews.
Geometry evidence for this build, separate from physical durability.
FINAL_VERIFICATION.json
JSON · 9 KB
SHA-256: ffc766f99e4ce6c63a227ecdae666324f384554fb3ce9576c8d8702cf8be3696PACKAGE_SHA256.json
JSON · 272 KB
SHA-256: ffce7c67b6603e2b31f5801dae26dc991e6150566b497735b74482898e186631Part_Manifest.json
JSON · 6 KB
SHA-256: 022ac0826020e8bf9d1ff74763f619218cd7ef3eed263049d16efce0b844790fUse this matched set together. Original engineering filenames are preserved.
Walkie_One_28_4_Complete_Handoff.zip
ZIP · 146.7 MB
Matched CAD, print parts, coupons, 16-page review, hardware, assembly instructions, verification, video and diagrams. Engineering identifiers remain 28.1 / R3.6.
SHA-256: 5b71bcbb3d3dd039b7258ae29fe436578ea88e9cbc57dfe8f6b5729618bc39d7Walkie_One_28_4_STL_Print_Set.zip
ZIP · 2.2 MB
24 rigid, 2 flexible-only and 2 optical fit proxies in separate folders. Millimetres; 100% scale. Orient and slice for your process.
SHA-256: a91445db12235c498059888e2f8068e5f8a159b1e5e519fbeeda7017716b4da1Walkie_One_28_4_Individual_STEP.zip
ZIP · 1.5 MB
SHA-256: 0cf58e1bb964b971fdeb307190ddd4e44d1b50177deb297f75ed1dac86a3273aEditable direct-solid F3D files, plus neutral STEP. Print-only and full reference assemblies are identified separately. Full reference CAD is for inspection, not slicing.
Walkie_One_28_1_R3_6_FULL_REFERENCE_ASSEMBLY.f3d
F3D · 7.5 MB
Assembly coordinates, millimetres. Editable direct solids.
SHA-256: 736131d384fbbdd241dad110d1f456f3c14414fcc2b803155f7411c994f42a6eWalkie_One_28_1_R3_6_FULL_REFERENCE_ASSEMBLY.step
STEP · 34.9 MB
Full reference assembly is for inspection only; print individual parts.
SHA-256: b7417a39d424a239e24c9a9934acfcf2ec56ede9beeaa9332cdfd337b052e3faWalkie_One_28_1_R3_6_PRINT_PARTS_ONLY.f3d
F3D · 2.9 MB
Assembly coordinates, millimetres. Editable direct solids.
SHA-256: 96cb8811b03e36d5e92cbc4d8b55e9b08777529ab2ee437ffb7fc3d050ddc315Walkie_One_28_1_R3_6_PRINT_PARTS_ONLY.step
STEP · 6.8 MB
Full reference assembly is for inspection only; print individual parts.
SHA-256: 300032b66e0d04a8f4470cb9993754d0c62d09d79090aa1dd75941b23c408999F01_Flexible_rim_bumper.stl
STL · 848 KB
Qualified flexible material
SHA-256: be2d84fd8790ffd92e45cc2ebdefb06880d91ed4ac1aee1ee628c8ca76447d89F02_Flexible_PTT_grip.stl
STL · 21 KB
Qualified flexible material
SHA-256: 78fa08e78eaebd5f5ae850822f8b1cc980e0d266982a5f186818268c812c6b13K01_Volume_up_capture.stl
STL · 32 KB
Qualified rigid structural process
SHA-256: b05f2c8e44cee68a5774e081b4a07dce5c98d04b4a5e34d0b52753c9e3201abcK02_Volume_down_capture.stl
STL · 32 KB
Qualified rigid structural process
SHA-256: 8310e9d959314ad4a3757dc739e779e0d3cb140761f399552ce44a3b7400d935K03_Battery_adapter_cover.stl
STL · 138 KB
Qualified rigid structural process
SHA-256: a0fe9f26a007787ab87fd88d55ad3babf3e1c2160e26cb4ff12a169f9cff219cL01_Lens_fit_proxy.stl
STL · 98 KB
Optical fit proxy; qualify clear material/optic
SHA-256: 75bb3eda84b4493018059645dad5280aa93365605e668894c21e39b8fe4208f7L02_Light_guide_fit_proxy.stl
STL · 546 KB
Optical fit proxy; qualify clear material/optic
SHA-256: b1bd666e7ec5a649a5fe623476d9b1c9cb5a8f594e0835cdf93ec82a40e93bacM04_Grille_bezel.stl
STL · 75 KB
Qualified rigid structural process
SHA-256: cdfe30a67dc9074c8018b20aed14806982ebc355f399f261b19629703efa4e53P01_Front_shell.stl
STL · 2.5 MB
Qualified rigid structural process
SHA-256: e4aa2033bad804ad4fd2e3026e7f3e2639869b6f2eaf034af60f0ece4aa7f69fP02_Rear_shell.stl
STL · 1.9 MB
Qualified rigid structural process
SHA-256: a17851ef53d96d4642d3c93d6803f8e040832461be8e7b53f6cf40513c5aabdeP03_Play_button.stl
STL · 169 KB
Qualified rigid structural process
SHA-256: dc43b254310dc2a1e3c7be604913f7b7de8e4cf1b4f5bbd713f0f7bc0893f66eP04_Play_switch_clamp.stl
STL · 193 KB
Qualified rigid structural process
SHA-256: 1b2aef35628133555bc45d74787b823a5685c51b8577855c928358e177185970P05_PTT_carrier.stl
STL · 115 KB
Qualified rigid structural process
SHA-256: 4af3051535b68d39fdf725315627aebd7c5658fdb336b1adefa030dc0caf9ca0P06_Volume_up_button.stl
STL · 177 KB
Qualified rigid structural process
SHA-256: 8e295d70bb06e2a6331f5c038ce864f84cabe5470ec67e1c6b513f7cfe583fbbP07_Volume_down_button.stl
STL · 167 KB
Qualified rigid structural process
SHA-256: 6300636fd5dd34dc02897b13906eb2d271533af39ed682ea06453fcfc3e89dcfP08_PTT_switch_cradle.stl
STL · 10 KB
Qualified rigid structural process
SHA-256: a08aa98e83f12b670c8a5d0c1ff877f375ec0730bbf460b28f1d1f632162bbf1P09_Volume_up_switch_cradle.stl
STL · 4 KB
Qualified rigid structural process
SHA-256: f0cac9f606865635dc7a0330238b65cb06eb00249df5521474d3ca6dc468b72aP10_Volume_down_switch_cradle.stl
STL · 4 KB
Qualified rigid structural process
SHA-256: 5b38ef89b60f270d7ff677f167923e2cd77a2f8e02802bcc4135dbdffb2007b5P11_Lower_speaker_keeper.stl
STL · 89 KB
Qualified rigid structural process
SHA-256: 3ef5d542f68ae207e836c40bcd4f52e8fa8e37cd711e113a6db5730ae3894300P12_Upper_speaker_keeper.stl
STL · 89 KB
Qualified rigid structural process
SHA-256: 953ce018a581180fd72ce39be7cfc12268bc7c65a2968446fa4be08955f2b780P13_Microphone_keeper.stl
STL · 157 KB
Qualified rigid structural process
SHA-256: 3987957b51b032e720e0468c93dd594129c3e859a64279a764e1255ed751da2fP14_LED_keeper.stl
STL · 202 KB
Qualified rigid structural process
SHA-256: 15305cfa31f3ba6fbcac2aad1e8a8a16b49b7d8ae28c2f903c041d17d2143cabP15_Lower_antenna_retainer.stl
STL · 71 KB
Qualified rigid structural process
SHA-256: daa702ae3304fc5d782273fe35db2684a4bcdbea2ffaab28fd9653bbf634c76dP16_Upper_antenna_retainer.stl
STL · 69 KB
Qualified rigid structural process
SHA-256: 7fe832faceedded6819e194e67dd4ae92e6b5238fff3ca400660a5e61cca8e58P17_Lower_PTT_guide.stl
STL · 140 KB
Qualified rigid structural process
SHA-256: f79ca0f1cb1e506e970e088fcf511bc39b35b03231c8640329e2a9524c1b23a7P18_Upper_PTT_guide.stl
STL · 141 KB
Qualified rigid structural process
SHA-256: 5f3c894f97a1677f64f05f946095cfeb079a4b72ba19249f4777e8382395100bP19_Left_battery_keeper.stl
STL · 91 KB
Qualified rigid structural process
SHA-256: 60ff7e3e23d63829ef9de5799f7877905df0a15b4735daa1c76b2a08638ec1dcP20_Right_battery_keeper.stl
STL · 133 KB
Qualified rigid structural process
SHA-256: 4222e4ca043bf0028ef3b49d79c0abf482c3dd37a924685ea1c990b506228877F01_Flexible_rim_bumper.step
STEP · 242 KB
Qualified flexible material
SHA-256: 791abab5732bc67b3add9f07396dd64f89294e6621a2be6f9db9459c6c6155c6F02_Flexible_PTT_grip.step
STEP · 14 KB
Qualified flexible material
SHA-256: 3aeee5c8cf20888a86902b90665d1511b518ad49e1a15009a403fe2523fba8efK01_Volume_up_capture.step
STEP · 33 KB
Qualified rigid structural process
SHA-256: f50bce1c2e290d9dab13b25dea5f322558cac87bf2e74b3c1a085a65b5a9d03eK02_Volume_down_capture.step
STEP · 33 KB
Qualified rigid structural process
SHA-256: b5d67e9e5d88ce07170faa6d9d262a0eefb2f622a59519126cf69ba221a60fc4K03_Battery_adapter_cover.step
STEP · 152 KB
Qualified rigid structural process
SHA-256: 13605e2ead9255ed870b477d218be26da6f7d5018df5f2ab9d8d0a2355b91baaL01_Lens_fit_proxy.step
STEP · 8 KB
Optical fit proxy; qualify clear material/optic
SHA-256: 7aa19a83e662ec3a13be1de03eb867d5c3461810d188245bcde2c83977e0c06dL02_Light_guide_fit_proxy.step
STEP · 18 KB
Optical fit proxy; qualify clear material/optic
SHA-256: eb9c48154d2c2da58083aaa470b6f0f0e55a8050b8902e53323a33a2e54deb52M04_Grille_bezel.step
STEP · 34 KB
Qualified rigid structural process
SHA-256: 3d0734ace4e3252fbbc1c2bc9acd212628a0f76ac5f6786753af99c3d9391e68P01_Front_shell.step
STEP · 2.8 MB
Qualified rigid structural process
SHA-256: 10d323dbf8019240036889d300c64b76522460986f1305846f1299120585ddc2P02_Rear_shell.step
STEP · 2.2 MB
Qualified rigid structural process
SHA-256: 9d16ab63dc5af12f6984b34d8f26eaba4b924dbee7c8f1999f26297d0fa9f427P03_Play_button.step
STEP · 70 KB
Qualified rigid structural process
SHA-256: 29318a1307ea4cee09f5d786a984416104463f7557a4b5b7410ce674bb96ae2dP04_Play_switch_clamp.step
STEP · 190 KB
Qualified rigid structural process
SHA-256: d06a77142cd6a1c3c98af0ef3a66671d7a364ba044266730b05f3df68515f4d7P05_PTT_carrier.step
STEP · 114 KB
Qualified rigid structural process
SHA-256: cb566a813a6ddeab1810bb73308438af695c8af81aa8d2cc6e960b1c1efa6fb6P06_Volume_up_button.step
STEP · 80 KB
Qualified rigid structural process
SHA-256: 876c6c9df29ecb3f2ffda4e348ddd23381e20446a45a4b4eaeb0def373068100P07_Volume_down_button.step
STEP · 64 KB
Qualified rigid structural process
SHA-256: 909ad0ab434b27f7c647b4f2190a891c708746b7609c7e184e45e7bb57444473P08_PTT_switch_cradle.step
STEP · 30 KB
Qualified rigid structural process
SHA-256: eaa0ddf7fc057f7b2faed21ee12931402c812fdc2d8d709fb9bb8165eee9ee52P09_Volume_up_switch_cradle.step
STEP · 30 KB
Qualified rigid structural process
SHA-256: a49f0e3a20530238fce2695870cc2bdbd50d096ae1ee5015b13d090262e92271P10_Volume_down_switch_cradle.step
STEP · 30 KB
Qualified rigid structural process
SHA-256: 2e254b18cef7b8b712f375185e083c414fefa3b3c683022e2e498d3fb6af9556P11_Lower_speaker_keeper.step
STEP · 22 KB
Qualified rigid structural process
SHA-256: d2d748e256f3381f9b8e2773f184438250e3f71477ceeb2d3437b9dad25877a2P12_Upper_speaker_keeper.step
STEP · 22 KB
Qualified rigid structural process
SHA-256: d0b37db75716affe372059fb0a5c3f4617c788522759a2451bdc55faf7fd7731P13_Microphone_keeper.step
STEP · 83 KB
Qualified rigid structural process
SHA-256: c98724ad5472ce38cc0d64697146039947ceaeddbff7f9b435a260961804281cP14_LED_keeper.step
STEP · 55 KB
Qualified rigid structural process
SHA-256: 037aefabd3cb3ef5b5420cf06b46c59bbccb6ecdfed497227b1fc5d92cc468faP15_Lower_antenna_retainer.step
STEP · 22 KB
Qualified rigid structural process
SHA-256: d1877acb627eaeb86efd13cba5c502ae45c1c990563d3215783fbf87a2df4f80P16_Upper_antenna_retainer.step
STEP · 38 KB
Qualified rigid structural process
SHA-256: 50fc819d532b3b64dfc8d6a0e01948d6f2b94041ebe6a74405c89d2896cf2359P17_Lower_PTT_guide.step
STEP · 54 KB
Qualified rigid structural process
SHA-256: 74bcbdd6c087fc5af476660eb0d7a9b37ec97063c2e084a2ba168b4ddceeeff1P18_Upper_PTT_guide.step
STEP · 57 KB
Qualified rigid structural process
SHA-256: 7c3e3b1b429a201b8dca9bc5d9d40e21170447c6ef7c9c8d430f6cfc30753882P19_Left_battery_keeper.step
STEP · 64 KB
Qualified rigid structural process
SHA-256: 08e472e49bf350ef7fe7e5cda888502a96d2c004219e12873c4579f59bba2039P20_Right_battery_keeper.step
STEP · 95 KB
Qualified rigid structural process
SHA-256: f0635caa6270066040ca37221f55f2d7b05fbcd1f14d6bf7117eb71e9d95f97eADAPTER_CARRIER_DRILL_AND_PAD_DRAWING.png
PNG · 307 KB
SHA-256: 3228e04e9a6f1b27af34fd63ced289537b243a75fe2748372715cc331c0d35dcADAPTER_CARRIER_DRILL_AND_PAD_DRAWING.svg
SVG · 19 KB
SHA-256: 910246814d8480d8ab6849138738708ea58c8c7e8ab06eda235151bf43d2bcfbADAPTER_CARRIER_FABRICATION.md
MD · 11 KB
SHA-256: 049ac0ece22a8f70513a1e42adb59ac9f2853cb5a4f5216b3e6f4ba254744b79ADAPTER_TWO_ISOLATED_NETS_AND_TERMINATION.png
PNG · 320 KB
SHA-256: 0940f29056bdeae9a983587ec3df1d02b743514005128e8dbdd55ae31bcc6c0cADAPTER_TWO_ISOLATED_NETS_AND_TERMINATION.svg
SVG · 13 KB
SHA-256: 325195fd33cf0adfc17e14695a96b8eaa18160eb992774fc761784b0f749b5cbAdapter_Final_Seat_and_Fasteners.md
MD · 6 KB
SHA-256: 643add110a89a4d3322c5896a96ef03be6399f07d9ecd757d9fac99fbd4ccc8dAnnotated_Component_Review.md
MD · 32 KB
SHA-256: 6bed81d2844ee84903e055bf7ebe22beb8cf3700793d900f9899088785f563fcAssembly_and_Qualification.md
MD · 18 KB
SHA-256: 71d433a78644487539c646d9030acef9987a722520445bf3a2729c4821693291Battery_Build_Notes.md
MD · 8 KB
SHA-256: 7aa59e0fa05ab830c557e9499c11e0f8414aecbacae9bb23af994f697ad98889Driver_Access_and_Fastening_Order.md
MD · 8 KB
SHA-256: aff0a3c63ad8a1e81a7aef6db63483e07ccd92f090fa4cd264856bb840ef0e5eFINAL_CONTROL_INTEGRATION_REVIEW.md
MD · 5 KB
SHA-256: 768c2c624d588cdaaec728fcdc4720567fb4787a538bdf52a69a21e54524dbcaFeature_Risk_Register.csv
CSV · 106 KB
SHA-256: 84cd6e084200f49d59c938fe9b9f406324adaae1e6ed3dd106cd59709dc804a0Feature_Risk_Register.md
MD · 122 KB
SHA-256: a5ee6eaea36f6cd139d7e2cb0eb68ad87348ec877bbe451f7b2a36f627943f2dFixture_Build_Notes.md
MD · 15 KB
SHA-256: 5211a19da16db2f024fff873851c52c05cb91dd1787945452ae2e45c6870f75fFixture_Final_Corrections.md
MD · 6 KB
SHA-256: 3c7b1411a297a74c88c6f946ca4131161c0f138eab5bda19439f36252ee024fcHardware_Schedule.csv
CSV · 2 KB
SHA-256: 3461aa26057889076876cc45d51ed6f179929a185dcdc1f28260d4af103d685aHardware_Schedule.md
MD · 3 KB
SHA-256: 7ba369163b68b34c0494defe51bae7944dd0622d9533c95fc62513f79ac6aa41J9_Harness_and_Stock.md
MD · 10 KB
SHA-256: 4aa7373e3aea262ad9c2296bf7fa459c4be41e967bea4d822b0747468c91bf76K03_REAR_ACCESS_REVIEW.md
MD · 7 KB
SHA-256: ffa09bd89675a10fb50d7ac774b4b3555ab6b352e08cdf70a84b41a20da42f5eMicrophone_Facing_Final_Correction.md
MD · 1 KB
SHA-256: 222d6413ca6bafa6dd15fa489d71a8c36bea6dc0ad57c1ebe87e0b82ee2a15b5Original_Reference_Disposition.csv
CSV · 22 KB
SHA-256: 0704d915fd5826505b6e53ac921f90aa34f592bd0d613a3800be7ba2e7ec13daPTT_REAR_PAD_STOCK_CORRECTION.md
MD · 3 KB
SHA-256: 96b06912aa205e69f964fc56d1ca052d6217980e7cb228ad863d79040291a713Physical_Qualification_Log.csv
CSV · 4 KB
SHA-256: ba40c8eff15760bd692cb99db580dcc6d98cc3c08f7dacce3e550ea8f486357eSoft_Stock_Installed_Envelopes.csv
CSV · 14 KB
SHA-256: ac46847000d7a47022aca612f6cfb4227c99335e11c30043dd8c6fee91308573Soft_Stock_and_Purchased_Parts.md
MD · 4 KB
SHA-256: 248839db1fc1a2055103a2fcdefed8513760b5a45105c40f88645182a4951456First print → Physical review → Golden decision
The next print tests this candidate. No physical durability result has been recorded for 28.4 yet.
The proposed stops and strength assumptions need physical validation. Review the results before making a separate Golden-version decision.
Current Golden version 28.1