> ## Documentation Index
> Fetch the complete documentation index at: https://docs.omi.me/llms.txt
> Use this file to discover all available pages before exploring further.

# Mechanical & Packaging

> STEP files for the Omi enclosure, charger dock, and retail packaging — organized by manufacturing process.

## Device Mechanical Design

The Omi is a 25.5mm diameter wearable pendant with aluminium covers and a PC+ABS internal frame.

### Full Assembly

* [`omi-device-charger-assembly.step`](https://github.com/BasedHardware/omi/blob/main/omi/hardware/consumer/mechanical/assemblies/omi-device-charger-assembly.step) — Complete device + charger dock STEP assembly

### 2D Drawings

* [`omi-2d-drawings.pdf`](https://github.com/BasedHardware/omi/blob/main/omi/hardware/consumer/mechanical/drawings/omi-2d-drawings.pdf) — Technical drawings for all parts
* [`manufacturing-specifications.png`](https://github.com/BasedHardware/omi/blob/main/omi/hardware/consumer/mechanical/drawings/manufacturing-specifications.png) — Manufacturing spec overview

<Frame caption="Manufacturing specifications and critical dimensions">
  <img src="https://raw.githubusercontent.com/BasedHardware/omi/main/omi/hardware/consumer/mechanical/drawings/manufacturing-specifications.png" />
</Frame>

<Frame caption="Cover prototypes for fit verification (SLA printed before CNC production)">
  <img src="https://raw.githubusercontent.com/BasedHardware/omi/main/omi/hardware/consumer/assembly/photos/outer-aluminium-covers.jpg" />
</Frame>

<Frame caption="All individual components before assembly">
  <img src="https://raw.githubusercontent.com/BasedHardware/omi/main/omi/hardware/consumer/assembly/photos/components-disassembled.jpg" />
</Frame>

***

## Parts by Manufacturing Process

<AccordionGroup>
  <Accordion title="CNC Machining" icon="gears">
    Aluminium covers and copper touch pins.

    | File | Description |
    | - | - |
    | [`case-a.step`](https://github.com/BasedHardware/omi/blob/main/omi/hardware/consumer/mechanical/parts/cnc/case-a.step) | Front cover (aluminium, D25.5mm) |
    | [`case-b.step`](https://github.com/BasedHardware/omi/blob/main/omi/hardware/consumer/mechanical/parts/cnc/case-b.step) | Back cover (aluminium, D25.5mm) |
    | [`touchpin-1-v2.step`](https://github.com/BasedHardware/omi/blob/main/omi/hardware/consumer/mechanical/parts/cnc/touchpin-1-v2.step) | Touch/charging pin 1 (copper, CNC) |
    | [`touchpin-2-v2.step`](https://github.com/BasedHardware/omi/blob/main/omi/hardware/consumer/mechanical/parts/cnc/touchpin-2-v2.step) | Touch/charging pin 2 (copper, CNC) |
    | [`touchpin-1.step`](https://github.com/BasedHardware/omi/blob/main/omi/hardware/consumer/mechanical/parts/cnc/touchpin-1.step) | Touch pin 1 (conductive copper, earlier version) |
    | [`touchpin-2.step`](https://github.com/BasedHardware/omi/blob/main/omi/hardware/consumer/mechanical/parts/cnc/touchpin-2.step) | Touch pin 2 (conductive copper, earlier version) |
    | [`cnc-brass-copper-zinc-polished.zip`](https://github.com/BasedHardware/omi/blob/main/omi/hardware/consumer/mechanical/parts/cnc/cnc-brass-copper-zinc-polished.zip) | Brass/copper variant with polished zinc finish |

    **Material:** Aluminium (covers), Copper or Brass + Zinc plating (touch pins)

    <Warning>
      **Critical:** Covers must be D25.5mm ±0.05mm. Touch pins must make reliable contact — test continuity after assembly. Poor pin contact is the #1 charger failure cause.
    </Warning>

    <Tip>
      For prototyping, 3D print the covers in SLA resin first to verify fit before committing to CNC aluminium (minimum orders typically 10-50 units).
    </Tip>
  </Accordion>

  <Accordion title="Injection Molding" icon="fill-drip">
    Internal shell/wrapper (OD 28.61mm, H 10.85mm, wall 0.7-1.34mm).

    | File | Description |
    | - | - |
    | [`wrapper.step`](https://github.com/BasedHardware/omi/blob/main/omi/hardware/consumer/mechanical/parts/injection-molding/wrapper.step) | Main wrapper/shell |
    | [`wrapper-drawing.pdf`](https://github.com/BasedHardware/omi/blob/main/omi/hardware/consumer/mechanical/parts/injection-molding/wrapper-drawing.pdf) | Manufacturing drawing |

    **Material:** PC+ABS
  </Accordion>

  <Accordion title="Silicone Molding" icon="droplet">
    Internal cushioning pad (D22.4mm, 0.6-0.9mm thick).

    | File | Description |
    | - | - |
    | [`pad.step`](https://github.com/BasedHardware/omi/blob/main/omi/hardware/consumer/mechanical/parts/silicone/pad.step) | Internal pad |
    | [`pad-drawing.pdf`](https://github.com/BasedHardware/omi/blob/main/omi/hardware/consumer/mechanical/parts/silicone/pad-drawing.pdf) | Manufacturing drawing |

    **Material:** Silicone, 50A or 80A durometer
  </Accordion>

  <Accordion title="SLA / Injection Molding (PC+ABS)" icon="print">
    Frame, LED guide, charger cases, and internal parts.

    | File | Description | Color/Finish |
    | - | - | - |
    | [`frame-white-translucent.step`](https://github.com/BasedHardware/omi/blob/main/omi/hardware/consumer/mechanical/parts/sla/frame-white-translucent.step) | Main frame | White translucent (or clear/transparent) |
    | [`led-guide-white-translucent.step`](https://github.com/BasedHardware/omi/blob/main/omi/hardware/consumer/mechanical/parts/sla/led-guide-white-translucent.step) | LED light guide | White translucent |
    | [`charger-case-a-ceramic.step`](https://github.com/BasedHardware/omi/blob/main/omi/hardware/consumer/mechanical/parts/sla/charger-case-a-ceramic.step) | Charger top case | Ceramic-like finish (or white) |
    | [`charger-case-b-ceramic.step`](https://github.com/BasedHardware/omi/blob/main/omi/hardware/consumer/mechanical/parts/sla/charger-case-b-ceramic.step) | Charger bottom case | Ceramic-like finish (or white) |
    | [`enhance-plate-black.step`](https://github.com/BasedHardware/omi/blob/main/omi/hardware/consumer/mechanical/parts/sla/enhance-plate-black.step) | Enhance plate | Black |
    | [`pad-ppt-grey.step`](https://github.com/BasedHardware/omi/blob/main/omi/hardware/consumer/mechanical/parts/sla/pad-ppt-grey.step) | PPT pad | Grey |
    | [`touchpin-2-sla-test.step`](https://github.com/BasedHardware/omi/blob/main/omi/hardware/consumer/mechanical/parts/sla/touchpin-2-sla-test.step) | Touch pin (SLA test variant) | Grey |

    **Material:** PC+ABS, SLA resin, or MJF nylon depending on finish

    <Note>
      All SLA parts can be printed on consumer SLA printers (Formlabs Form 3/4, Elegoo Saturn). Use white/translucent resin for the frame and LED guide — these need to transmit light.
    </Note>
  </Accordion>
</AccordionGroup>

***

## Packaging

Retail packaging 3D models for manufacturing the box, foam inserts, and protective case.

### CAD Files

| File | Description |
| - | - |
| [`packaging-full-assembly.step`](https://github.com/BasedHardware/omi/blob/main/omi/hardware/consumer/packaging/cad/packaging-full-assembly.step) | Complete packaging assembly |
| [`case-packaging.step`](https://github.com/BasedHardware/omi/blob/main/omi/hardware/consumer/packaging/cad/case-packaging.step) | Outer case |
| [`sheet-metal-packaging.step`](https://github.com/BasedHardware/omi/blob/main/omi/hardware/consumer/packaging/cad/sheet-metal-packaging.step) | Sheet metal insert |
| [`foam-assembly.step`](https://github.com/BasedHardware/omi/blob/main/omi/hardware/consumer/packaging/cad/foam/foam-assembly.step) | Foam insert assembly |
| [`foam-top.step`](https://github.com/BasedHardware/omi/blob/main/omi/hardware/consumer/packaging/cad/foam/foam-top.step) | Top foam piece |
| [`foam-bottom.step`](https://github.com/BasedHardware/omi/blob/main/omi/hardware/consumer/packaging/cad/foam/foam-bottom.step) | Bottom foam piece |
| [`foam-circle.step`](https://github.com/BasedHardware/omi/blob/main/omi/hardware/consumer/packaging/cad/foam/foam-circle.step) | Circular foam cutout |
| [`foam-packaging.step`](https://github.com/BasedHardware/omi/blob/main/omi/hardware/consumer/packaging/cad/foam/foam-packaging.step) | Foam packaging shell |
| [`foam-drawing.pdf`](https://github.com/BasedHardware/omi/blob/main/omi/hardware/consumer/packaging/cad/foam/foam-drawing.pdf) | Foam manufacturing drawing |
| [`package-drawing.pdf`](https://github.com/BasedHardware/omi/blob/main/omi/hardware/consumer/packaging/package-drawing.pdf) | Package technical drawing |

### Reference Photos

Photos of the assembled packaging are in [`packaging/photos/`](https://github.com/BasedHardware/omi/tree/main/omi/hardware/consumer/packaging/photos) for manufacturing reference.

***

## Ordering Guide for Indie Makers

<Steps>
  <Step title="Start with SLA-printed parts">
    Print the frame, LED guide, charger cases, enhance plate, and pad on your SLA printer. Total print time: \~4-6 hours. Cost: \~\$5 in resin.

    <Tip>No SLA printer? Services like JLCPCB 3D Printing, Craftcloud, or Shapeways accept STEP files directly.</Tip>
  </Step>

  <Step title="Order CNC aluminium covers">
    Upload `case-a.step` and `case-b.step` to a CNC service. Specify 6061 aluminium, anodized finish. Typical lead time: 5-10 days, \$10-30/unit at 10+ quantity.
  </Step>

  <Step title="Source silicone pad and wrapper">
    For prototyping, 3D print the silicone pad in flexible resin (Formlabs Flexible 80A). The wrapper can be SLA printed in rigid resin.

    <Note>True silicone molding and injection molding only make economic sense at 500+ units.</Note>
  </Step>

  <Step title="Buy off-the-shelf parts">
    Order from standard suppliers: N52 magnets (D3×H3mm), Phillips screws (CM1.2×5), necklace rope (2.5mm), dust filters, double-sided tape. All available on AliExpress/Amazon.
  </Step>
</Steps>


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