Experimental prototype / September 16, 2026

Simplified

Same idea. Far fewer parts.

A clean-sheet Fusion enclosure for the existing electronics. The Chalk Ember inspiration stays; the construction is simpler.

8 printed parts6 screws

Width: 78 mm
Height: 150 mm
Depth: 24 mm

Maximum assembled envelope, including side buttons. No increase in size.

Download print package

Watch the 1:40 explainer Open 3D

Digitally checked prototype. The first physical assembly is still to be tested.

Chalk EmberSimplified

Version Simplified CAD preview in Chalk Ember

Loading the 3D model…

Released S1 CAD: eight printed parts plus the PCB, battery, speaker, microphone, switches, LED, modem and antenna references. Inside removes the rear cover and its battery/antenna. Nominal reference dimensions remain subject to physical fit checks. Hardware, wiring and the future rubber band are not shown.

Open full-resolution image

Rotate, zoom, or choose Assembled, Inside and Exploded. The viewer includes the eight prints and placed electronics references. S1 remains the engineering file identifier.

The simplified version, explained

What changed, how it goes together, and what comes next.

Download video Read transcript

Eight parts. That’s the printed assembly.

Down from 21 printed parts and 22 screws in 28.5.

The eight S1 prints: front shell, rear cover, talk, volume up, volume down, play, control bridge and light guide

01Front shell
02Rear cover
03Talk paddle
04Volume up
05Volume down
06Play button
07Control bridge
08Clear light guide

Seven PETG parts and one clear resin light guide. Broad built-in seats replace the separate PCB carrier and small retaining brackets. Four screws close the case; two secure the control bridge.

Inside the simpler construction

The same components, housed in fewer printed parts.

Exploded S1 CAD showing the flat PCB, battery and rear cover — Component packing from the actual CAD. Reference geometry is nominal where noted in the assembly brief.

The existing handful of components

The PCB lies flat, component side toward the front. The battery, speaker, Adafruit SPH0645 microphone, four switches, LED, antenna and wiring occupy simple mounting areas.

One open speaker hole

A single Ø35 mm opening. Nothing crosses it: no printed bars, backing or mesh. The speaker frame sits behind the rim and the cone stays exposed.

Walls with substance

2.4 mm side and rear walls. A 3.0 mm front skin and 4.0 mm reinforced bridge arm. Button flanges are 2.4 mm, with positive travel stops and no thin snap hooks.

Later revision / still required

The rubber band is not included yet.

Simplified has a rigid printed perimeter in warm grey. A separate rubber or TPU bumper remains part of the plan. Its interface still needs to be designed.

The future rigid shell must make room for that band within the same 78 × 150 × 24 mm overall limit. Adding it must not make Walkie One larger.

A straightforward assembly

Use the included print and assembly brief for material settings, pads, hardware sizes and fitting details.

01
Prepare the prints
Remove supports, clean the fits and install the six M3 inserts. Trial-fit the empty shells and buttons.
02
Seat the speaker and microphone
The speaker frame mounts behind the open hole with an adhesive foam ring. The Adafruit SPH0645 microphone uses its small acoustic gasket and open locating seat.
03
Fit the controls
Load the four caps from the rear. Fit the switches, existing LED and clear light guide, then secure the single control bridge with two M3 × 6 screws.
04
Lay the PCB flat
Connect the existing harness and lower the PCB onto its built-in supports, component side toward the front. Check real plugs, terminal legs and wire turns.
05
Add the rear components
Fit the antenna, soft pads and battery in the rear cover. Keep wiring clear of the screw posts, supports and seam.
06
Close and check
The cover should seat by hand. Use four M3 × 12 screws, then check charging, all controls, microphone, speaker, indicator and radio operation.

The digital solid, clearance and sample slicing checks pass. The seven rigid parts took about 3 h 58 min and 112 g in the sample P1S PETG slice, including supports and brim. Actual fit, wiring, button feel, audio, light output, radio performance and strength still need a physical first article.

The Simplified files

The files retain their S1 engineering identifier. Print one of each of the eight STL files at 100% in millimetres. STEP files are alternative formats for the same parts.

Print package · start here

Walkie_One_S1_Print_Package.zip

ZIP · 6.0 MB

Eight bed-oriented STL files, matching STEP alternatives, print brief and assembly instructions. Seven PETG parts plus one clear resin guide.

File checksum

SHA-256: b980bf2e15e53b410088e312aa4913529dbc535b390e9191346cbfa1a67e8d7e

The simplified version, explained

Eight parts. That’s the printed assembly.

Inside the simpler construction

The existing handful of components

One open speaker hole

Walls with substance

The rubber band is not included yet.

A straightforward assembly

Prepare the prints

Seat the speaker and microphone

Fit the controls

Lay the PCB flat

Add the rear components

Close and check

The Simplified files

Print package · start here

Fusion and editable source

Native Fusion · eight print parts

Print and assembly instructions

01 Front Shell

02 Rear Cover

03 Talk

04 Volume Up

05 Volume Down

06 Play

07 Control Bridge

08 Light Guide CLEAR

01 Front Shell · STEP alternative

02 Rear Cover · STEP alternative

03 Talk · STEP alternative

04 Volume Up · STEP alternative

05 Volume Down · STEP alternative

06 Play · STEP alternative

07 Control Bridge · STEP alternative

08 Light Guide CLEAR · STEP alternative

Full Fusion assembly · includes purchased references

Eight print parts · combined STEP

Read first · release and bumper status

Foam and gasket cut outlines

Digital release checks

The same Chalk Ember inspiration.