Tony's 3D print project 🖨️
Progress page for Tony and Sam. Updated as the work moves.
Status
Test-fit coupons — downloads available, unverified
Six small test-fit pieces are built: three radio-collar clearances and three straight whip-base clips. Independent review passed corrected edges and frozen-file coherence. The corrected download package passed independent hash verification and is released for unverified test fitting only. Physical fit is unverified, and the printer bed and nozzle still need checking. The full organizer has not passed layout review.
Test-fit coupons — TEST-FIT, UNVERIFIED
These small pieces test the radio collar, charging-cell alignment and straight whip-base clip. They are not the organizer. Each part is smaller than about 82 × 27 × 25 mm, with its flat bottom on the bed and open side up.
Before printing: confirm the actual bed and nozzle in the slicer. ASA is confirmed; 0.4 mm nozzle is assumed. Radio dimensions, charging-jack location and the assumed 10 mm plug body need physical checking. The clip needs about 0.3 mm flex per side; ASA snap performance is unverified. Do not force it; stop if it whitens or cracks.
A1 / A2 / A3: 0.3 / 0.6 / 1.0 mm radio wall gap per side. B1 / B2 / B3: 15.3 / 15.6 / 16.0 mm bore, all with a 14.4 mm throat. One, two or three recessed dots identify the variant.
Disclosed differences: the 20 mm radio collar has no finger scallop; lift by the exposed radio ends. Wall-top rounding is 1.1 mm. Charging access is modelled on one side only.
Corrected revision: rounded edges have passed model review. Inspect the printed handling edges, charging-cell rims and shaft-guide exits before use; printed abrasion behaviour is untested.
Test-only deviations: measured model plug-body/barrel gaps are 0.988470 / 3.998470 mm; a maximum 0.05 mm mesh allowance is accepted. Clip arms are experimental 2.4 mm ASA; strength and recovery are unverified. Rough B1/B2/B3 strain estimates are 1.88% / 1.69% / 1.50%, not tested ASA limits. Concave roots concentrate stress; insert gently and stop on force, whitening or cracks. Full-antenna insertion clearance remains unchecked. These files are not printer-ready until the actual bed and nozzle are checked; support-free printing is intent, not verified slicer performance.
Revision 2ea1970: all 12 STL/STEP copies and ZIP members match the reviewed frozen files. Released for TEST-FIT, UNVERIFIED use only; not printer-ready. Package verification passed; physical fit and ASA snap behaviour remain unverified. The unchanged packaged instructions retain their pre-release pending label; this page records the subsequent test-fit release decision, not print approval.
Download all six test-fit coupons (STL + STEP + instructions) · Read test instructions and risks · SHA256 checksums
Images below are earlier illustrative test-coupon renders, not evidence of the current download revision.
Plan
What we're making: a 3D-printable organizer that sits inside a soft radio bag. It is a smooth, rounded "pebble" shape with an open cellular lattice (think Wilson's airless basketball). It holds four Baofeng UV-5R 8W radios with extended batteries, two folded flat-band antennas and two whip antennas. The charging ports stay reachable while the radios are seated.
How we'll build it (in order):
- Reference models. Source-labelled radio envelope, antenna and charging-plug models; actual-radio geometry remains unverified.
- Layout and solid fit. Place everything inside the bag's usable space (360 × 147 × 72.5 mm max) with clearances. Then build a solid pebble body with cradles. You'll see renders, including the underside and cut-through views.
- Lattice. Turn the solid body into the open cellular lattice, with no loose bits, spikes or chopped-off struts.
- Print split. Check it against Tony's printer bed. One piece if it fits, otherwise joined sections.
- Final files. Editable CAD source, print-ready meshes, and a 3D preview you can spin right on this page.
Team: a lead who keeps it on spec, a CAD engineer, and a separate reviewer who checks every stage from the actual renders and measurements. Independent fit feedback is checked at each stage.
Still needed from Tony (we'll design around assumptions until then, and flag them):
- Printer model and build volume. The organizer is about 35 cm long, which is bigger than most printer beds, so it will likely print in joined sections.
- Material is confirmed as ASA. Nozzle size is still unknown; the design assumes 0.4 mm.
- Photos or measurements of his actual radio with the extended battery, especially around the charging port.
- The charging plug's connector body size, beyond the 3.98 mm barrel.
Progress log
- Oct 12, 2026: Corrected test-fit coupon geometry and frozen-file coherence passed independent review. Download package hash verification passed; released as TEST-FIT, UNVERIFIED only. ASA confirmed; actual fit remains unverified.
- Oct 12, 2026: Reference phase accepted for modelled envelopes only. No organizer or printability approval yet. Layout work can now proceed; printer bed and nozzle details are still needed before claiming printer readiness.
- Oct 12, 2026: Antenna reference renders added and envelope review passed. A straight planar diagonal cannot hold the 380 mm whip; flexible-shaft routing remains to be checked.
- Oct 12, 2026: Project page created. Brief received, plan written, team set up. Reference work is underway.
Radio reference renders — envelope review passed
Modelled envelope: 152.15 × 59 × 34.5 mm. This is not an accurate radio model. Knob shape, port side, battery details and connector body are assumptions; real fit needs a test print. No battery-guide retention is inferred.
Only the battery region is extended; the housing is not scaled and the battery is not made wider.
Antenna reference renders — envelope review passed
The rigid base stays straight (54.42 mm). The nominal 380 mm length is provisionally measured from base face to tip; including the thread gives 382.97 mm. Thread clearance and the band’s rounded edges are assumptions. Flexible-shaft bend limits and physical fit remain unverified.
Preview and downloads
The finished, print-ready files (STL/3MF) and print settings will be posted here.