Assembly and BOM

Bill of materials

• CSV format
• XLSX format

Key components

Passive components

Assembly reference

Exploded view

1. Front aluminum cover (CNC machined)
2. LED light guide (SLA/translucent)
3. Main frame (SLA/translucent PC+ABS)
4. PCB mainboard with microphones, SoC, flash
5. FPC connecting to charging contacts
6. Battery (150mAh LiPo)
7. Vibration motor
8. Silicone pad
9. Back aluminum cover (CNC machined)

Build guide

• Core assembly
• Packaging and QA

1

Prepare the workspace

Lay out all components on an anti-static mat. You’ll need: tweezers, Phillips screwdriver (PH000), UV lamp, multimeter, and S300 adhesive.

2

Install the PCB into the frame

Place the mainboard PCB into the SLA frame on the mounting posts. Board should sit flat with no rocking. Connect the FPC cable to the board-to-board connector.

The FPC connector is fragile. Lift the latch before inserting, then press down firmly to lock. Do not force it.

3

Connect the battery and motor

Plug in the 150mAh LiPo battery. Route the cable to avoid pinching. Attach the vibration motor with double-sided tape.

Battery polarity is critical. Reversed polarity will destroy the BQ25101 charger IC and may cause thermal runaway. Verify polarity with a multimeter before connecting.

4

Install magnets and the silicone pad

Apply UV adhesive to magnet seats. Insert 4x N52 magnets (D3×H3mm). Cure with UV lamp for 30 seconds each.

Test magnet polarity against the charger dock BEFORE gluing. Mark each magnet with a Sharpie. Once cured, they cannot be removed.

Place the silicone pad over the battery/motor assembly.

5

Close the enclosure

Attach aluminum covers (Case A front, Case B back). Secure with 3x Phillips screws (CM1.2×5). Apply S300 glue around the seam.

Before sealing: test charging contact continuity, verify BLE advertising, confirm both mics record audio.

1

Final device QA

Power on the device and run through the verification checklist:

• BLE advertising visible in nRF Connect
• Both microphones recording (test with firmware audio loopback)
• Wi-Fi scanning networks
• IMU reporting orientation changes
• LED cycling RGB colors
• Charger dock making contact and charging

All 6 checks must pass before packaging.

2

Package the device

Place device in foam insert, close the packaging case. The foam inserts protect the device during shipping.

Packaging STEP files are in packaging/cad/ if you want to manufacture custom retail packaging.

Reference photos

• materials-labelled-exploded-view.jpg: all components identified
• materials-labelled.jpg: materials and finish callouts
• components-disassembled.jpg: individual components laid out
• outer-aluminium-covers.jpg: CNC aluminum cover detail

Additional mechanical parts

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