This instruction covers only the present unpowered, 3D-printed mechanical kit. The RP2350 calculator PCB has not yet been fabricated, so this is a fit-and-assembly guide, not a working-electronics build.

Parts and source files

• chassis_award.stl
• unified_faceplate_award.stl
• tpu_membrane_award.stl
• top_cap_award.stl

Use these four files as a matching set. Do not substitute the exploratory print-in-place spring fixtures or older faceplate variants. Download the matching PrusaSlicer .3mf files from the project Files area. They preserve the model orientation and per-part overrides; open them without rotating or rescaling the model.

Reference print profiles

These are the overrides embedded in the supplied .3mf files, prepared for a Prusa MK4S with a 0.4 mm high-flow nozzle. They are reference starting points for this prototype, not qualified production settings. Run a small fit check when changing filament, nozzle, or printer.

Chassis — chassis_award_petg.3mf

• Material: PLA, Generic PLA @MK4S HF0.4, 1.75 mm.
• Structure: 0.20 mm layers and first layer; 2 perimeters; 5 top / 3 bottom layers; 15% gyroid; 0.20 mm elephant-foot compensation; aligned seam; external fuzzy skin with 0.5 mm point distance and 0.2 mm thickness.
• Support: 5 mm outer brim. Manual snug supports at 35° with a 0.20 mm contact gap and 3 interface layers; supports may begin away from the build plate.
• Thermal and motion: 225°C nozzle / 230°C first layer; 60°C bed; first layer 40 mm/s; perimeters 250, outer 200, infill 250, bridges 50 mm/s; fan 70–100% after layer 1.

Unified faceplate — unified_faceplate_award_pla.3mf

• Material: PLA Silk, Generic PLA Silk @MK4S, 1.75 mm.
• Structure: 0.15 mm layers, 0.20 mm first layer; 2 perimeters; 6 top / 4 bottom layers; 15% grid; 0.20 mm elephant-foot compensation; aligned seam.
• Support: No brim. Automatic snug supports from the build plate only at 35°, with a 0.17 mm contact gap and 3 interface layers.
• Thermal and motion: 225°C nozzle / 230°C first layer; 60°C bed; first layer 40 mm/s; perimeters 250, outer 200, infill 250, bridges 45 mm/s; fan 70–100% after layer 1.

TPU membrane — tpu_membrane_award.3mf

• Material: Flexible TPU, AmazonBasics TPU @MK4S, 1.75 mm.
• Structure: 0.10 mm layers, 0.20 mm first layer; 2 perimeters; 8 top / 7 bottom layers; 15% grid; 0.20 mm elephant-foot compensation; rear seam.
• Support: No brim. Manual snug supports at 40°, with a 0.17 mm contact gap and 3 interface layers; supports may begin away from the build plate.
• Thermal and motion: 235°C nozzle and first layer; 50°C bed; first layer 40 mm/s; perimeters, outer walls, and infill 140 mm/s; bridges 40 mm/s; fan 50–60% after layer 4.

Top cap — top_cap_award_petg.3mf

• Material: PLA, Generic PLA @MK4S HF0.4, 1.75 mm.
• Structure: 0.20 mm layers and first layer; 2 perimeters; 5 top / 3 bottom layers; 15% gyroid; 0.20 mm elephant-foot compensation; aligned seam.
• Support: No brim. Manual snug supports at 35°, with a 0.20 mm contact gap and 3 interface layers; supports may begin away from the build plate.
• Thermal and motion: 225°C nozzle / 230°C first layer; 60°C bed; first layer 40 mm/s; perimeters 250, outer 200, infill 250, bridges 50 mm/s; fan 70–100% after layer 1.

Naming note: chassis_award_petg.3mf and top_cap_award_petg.3mf retain historical filenames, but their embedded slicer profiles identify PLA. Use the embedded profile and these settings as the source of truth.

Assembly

1. Print the four matching parts from the corresponding .3mf projects. Remove support material carefully from mating surfaces; do not cut or abrade the TPU membrane's flexible features.
2. Dry-fit the unified faceplate and TPU membrane in the chassis rails. Keep the parts square to the rails and stop if a feature binds; do not force the printed parts into place.
3. Align the top cap with the chassis catch pockets and press it into the snap-retention features. The cap is intended to close the printed assembly without screws.
4. Inspect the assembly for pinched membrane material, uneven seating, or stressed snap features. To reopen it, release the retention features rather than prying against the display surround or flexing the chassis unnecessarily.

Current limit

There is no PCB, display, battery, or powered calculator in this build. Key force, retention fatigue, service life, and final fit still need measurement on matching physical specimens.

See the project files for the current exports and StackCalc.io for the source hardware guide.