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Device Mechanical Design

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

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Full Assembly

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2D Drawings

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Parts by Manufacturing Process

Aluminium covers and copper touch pins.
FileDescription
case-a.stepFront cover (aluminium, D25.5mm)
case-b.stepBack cover (aluminium, D25.5mm)
touchpin-1-v2.stepTouch/charging pin 1 (copper, CNC)
touchpin-2-v2.stepTouch/charging pin 2 (copper, CNC)
touchpin-1.stepTouch pin 1 (conductive copper, earlier version)
touchpin-2.stepTouch pin 2 (conductive copper, earlier version)
cnc-brass-copper-zinc-polished.zipBrass/copper variant with polished zinc finish
Material: Aluminium (covers), Copper or Brass + Zinc plating (touch pins)
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.
For prototyping, 3D print the covers in SLA resin first to verify fit before committing to CNC aluminium (minimum orders typically 10-50 units).
Internal shell/wrapper (OD 28.61mm, H 10.85mm, wall 0.7-1.34mm).
FileDescription
wrapper.stepMain wrapper/shell
wrapper-drawing.pdfManufacturing drawing
Material: PC+ABS
Internal cushioning pad (D22.4mm, 0.6-0.9mm thick).
FileDescription
pad.stepInternal pad
pad-drawing.pdfManufacturing drawing
Material: Silicone, 50A or 80A durometer
Frame, LED guide, charger cases, and internal parts.
FileDescriptionColor/Finish
frame-white-translucent.stepMain frameWhite translucent (or clear/transparent)
led-guide-white-translucent.stepLED light guideWhite translucent
charger-case-a-ceramic.stepCharger top caseCeramic-like finish (or white)
charger-case-b-ceramic.stepCharger bottom caseCeramic-like finish (or white)
enhance-plate-black.stepEnhance plateBlack
pad-ppt-grey.stepPPT padGrey
touchpin-2-sla-test.stepTouch pin (SLA test variant)Grey
Material: PC+ABS, SLA resin, or MJF nylon depending on finish
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.

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Packaging

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

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CAD Files

FileDescription
packaging-full-assembly.stepComplete packaging assembly
case-packaging.stepOuter case
sheet-metal-packaging.stepSheet metal insert
foam-assembly.stepFoam insert assembly
foam-top.stepTop foam piece
foam-bottom.stepBottom foam piece
foam-circle.stepCircular foam cutout
foam-packaging.stepFoam packaging shell
foam-drawing.pdfFoam manufacturing drawing
package-drawing.pdfPackage technical drawing

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Reference Photos

Photos of the assembled packaging are in packaging/photos/ for manufacturing reference.

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Ordering Guide for Indie Makers

1

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.
No SLA printer? Services like JLCPCB 3D Printing, Craftcloud, or Shapeways accept STEP files directly.
2

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.
3

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.
True silicone molding and injection molding only make economic sense at 500+ units.
4

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.