> ## 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>