Mechanical & Packaging - Omi

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 — Complete device + charger dock STEP assembly

2D Drawings

omi-2d-drawings.pdf — Technical drawings for all parts
manufacturing-specifications.png — Manufacturing spec overview

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`	Complete packaging assembly
`case-packaging.step`	Outer case
`sheet-metal-packaging.step`	Sheet metal insert
`foam-assembly.step`	Foam insert assembly
`foam-top.step`	Top foam piece
`foam-bottom.step`	Bottom foam piece
`foam-circle.step`	Circular foam cutout
`foam-packaging.step`	Foam packaging shell
`foam-drawing.pdf`	Foam manufacturing drawing
`package-drawing.pdf`	Package technical drawing

Reference Photos

Photos of the assembled packaging are in 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>