Assembly & BOM

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Bill of Materials

• CSV format
• XLSX format

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Key Components

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Passive Components

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Assembly Reference

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Exploded View

1. Front aluminium 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 aluminium cover (CNC machined)

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Build Guide

• Core Assembly
• Packaging & QA

1

Prepare 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 PCB into 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 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 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 enclosure

Attach aluminium 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.

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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 aluminium cover detail

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Additional Mechanical Parts

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File Integrity

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