thereprocase
The original transition.
The wall pads extend beyond the arm’s 12 mm thickness. The section just above that layer was small.
MINIMALIST M1.1 / OPEN FRAME PROTOTYPE
Hold the laptop.
Leave the air open.
Two lighter arms. Two open fan cradles. An optional, positively indexed airflow dam.
A new native FreeCAD fork, with measured size examples and removable printed hardware. Rev H continues below as the preserved ducted prototype.
Explore Minimalist ↓ View ducted Rev H ↓
Inspect the current geometry below, then follow the print and assembly record.
Open print guide →MINIMALIST / ACTUAL PARAMETRIC CADDrag to orbit · Pinch or scroll to zoom
M1.1 / REINFORCED WALL JUNCTIONSSee the change and upgrade instructions ↗
Paired webs carry into the arm.
Taller 32 mm wall pads and two 6 mm tapered webs per pad continue to the print bed face. Gold highlights added material; each arm remains one fused print.
More section, a modest print cost.
At the sampled transition layer, each junction grows from 192 to about 416 mm². The complete nominal set adds 12.50 g and 17 m 36 s over M1.0. This geometry comparison does not establish physical strength.
Upgrade both arms and, if fitted, both dams with the matching clearance notch. The other sixteen parts keep their geometry. All six sizes and nine dam positions were rechecked.
Inspect the section data ↗401g
Full nominal set
Orca ASA estimate
66%
Less estimated filament
than the complete Rev H set
54/54
Native size × dam-position
checks passed
0.30mm
Nominal printed
mating clearance
WHAT CHANGED / WHAT IS CHECKEDRead the release evidence ↗
Airflow parts can come off.
The arms support the laptop. Open cradles hold two 120 mm fans at 45°. The upper dam is optional; its two halves and their keys and keepers can be removed as six separate parts.
Adjustment has a positive stop.
Withdraw the keeper, slide out the two-rung key, move the dam, then reinstall both. The key carries the attachment load; the split keeper prevents withdrawal. Print the fit coupon before the full set.
A print candidate with measured evidence.
All nominal plate paths were screened: no disconnected floating components. The expanded screen measures both bridge moves and overhang-wall paths; those results are listed in the release evidence. Native parts, mesh closure, STEP roundtrips, service clearances and plate placement were checked.
Physical fit, printed retention, long-term ASA creep, wall anchors and cooling performance still need qualification. The section calculation reports stress demand; it does not establish a load rating.
Download the eight-piece fit coupon plate ↓DUCTED PRECISION 5560 PROTOTYPE · REVISION H
The fit &
finish edit.
Small details. A much more deliberate assembly.
Rounded transitions, consistent clearances and print-aware reliefs — rebuilt live, around the arms already on the printer.
Explore the actual CAD ↓01 / THE REAL GEOMETRYDrag to orbit · Scroll or pinch to zoom
0.30mm
Measured fan-interface
and rail-to-arm gaps
14/ 14
Valid installed solids
in the Rev H STEP
176
Fully constrained
native sketches
0mm³
Change to either
printed arm
ANATOMY / SIX PART FAMILIES
Everything in its place.
Even pulled apart.
- Outlet railsClosed roofs, contoured arm reliefs, open exhaust.
- Printed armsRetained for this prototype. Future arms can change.
- Fan ductsLofted air path and separate wall closure patches.
- Sliding traysGrille-down prints and 0.30 mm mating clearances.
- Retainer capsOriginal rounded outline and cable opening.
- Four push-pinsOriginal split-crown retention preserved.
02 / THE FIX LISTSelect a card to inspect its part in 3D
The little things
that weren’t little.
03 / MADE FOR THE NEXT EDITNative all the
Native all the
way through.
Editable sketches and native features, shared design parameters, installed part placements, and a separate measured-fit review sheet.
Live edits were grouped into complete operations to avoid a recompute after every small step. The application log and saved validation reports kept the result reviewable.
SketcherPart / PartDesignAssemblySpreadsheet
A familiar workspace, a native model.
Matte teal materials, technical edges, a solid lighter background and a Fusion-inspired command ribbon. Installed Fusion definitions have also been inventoried; this screenshot shows the current approximation.
REV H / TRANSIENT COMMISSIONINGVALIDATION NOT ACCEPTED
Inspect the startup evidence.
The H mesh has 18.2 million cells with 0.25 mm edge targets. Expanded mesh checks fail, and the diagnostic restart completed only 0.0203084 ms of the planned 2 ms. This is a commissioning checkpoint: shedding, Bernoulli suction and validation are not established.
Open the Rev H report, raw samples, plots and four-frame startup animation ↗
AIRFLOW / BEHIND THE DESIGNEXPLORATORY REV F BASELINE
Follow the flow.
From the angled fan inlets, through the rear plenum, toward the laptop intake and hinge outlet. Actual simulation plots make the airflow assumptions visible.
This is an uncalibrated, non-thermal baseline study. The 3D run reached its iteration limit without meeting the strict convergence target. It does not establish cooling performance, and no accepted Revision H airflow result is presented here. The Rev H transient commissioning report is now available: 18,219,444 cells, 0.25 mm edge targets, failed expanded mesh checks, and only 0.0203084 ms completed of the planned 2 ms. Its raw samples, plots and four-frame startup animation are diagnostic evidence. Shedding, Bernoulli suction and validation are not established. Assumptions and full run notes ↗
The earlier pin-overlap check below treated all pin contact as intentional. It missed the socket wall obstruction corrected in D4. Read the current socket checks ↗.
04 / MEASURED, NOT JUST EYEBALLEDOpen the audit JSON ↗
The fit report.
Revision H: three R12 airway blends per duct, with R14 exterior support. Sampled new curved walls remain above 1.60 mm and new curved overhangs below 40° in the inlet-down print orientation. See the geometric checks ↗
| Interface / check | Result |
|---|---|
| Cap ↔ duct · left + right | 0.300 mm |
| Cap ↔ tray · left + right | 0.300 mm |
| Tray ↔ duct · left + right | 0.300 mm |
| Rail ↔ frozen arm · left + right | 0.300 mm |
| Four duct keys ↔ frozen receivers | ≥ 0.300 mm |
| Unintended assembly interference | 0 mm³ |
| Laptop, fan + wall-driver interference | 0 mm³ |
| Sampled insertion + service motions | PASS |
H-C1 / FAN CABLE ROUTINGExplore cable routing and printing ↗
Lay in the wire. Close the cover.
A rounded groove at the mating edge lets the fan connector stay outside. Two zip-tie anchors on each tray route the wire along its outside rail and stay put when the cover comes off. Replace covers 05/06 and trays 09/10; keep the arms, ducts, rails, pins and optional H-R1 retainers.
Open at the mating edge.
Lay the wire in before fitting the cover. The tray closes the passage; no connector needs to be threaded through a hole.
Tie anchors on the tray.
One near the exit, one farther along the outside rail. Leave slack for servicing and keep the cable clear of the rotor.
Test the actual cable first.
The small corner coupon reproduces the groove, tray, duct latch and pin. Geometric checks use a 4 mm cable with 0.5 mm minimum clearance; actual fit, abrasion and tie-lug strength remain untested.
Print and fit the coupon ↗H-R1 / REMOVABLE RETENTION ADD-ONExplore the model and installation guide ↗
Keep the arms you printed.
Two external side bars and two keyed keepers retain the Rev H ducts and upper rails. They use existing arm windows; all fourteen Rev H parts keep their geometry. Start with the short fit coupon on your printed right arm.
Four added parts.
Slide the bars inward, then insert the keepers from below. Removing one bar releases both the duct and rail on that side; support both during service.
Existing windows provide the catch.
Two keys limit rotation; a lower heel and wider upper stop preserve overlap. The green keeper foot catches the inner gusset face. Physical fit, retention and warm ASA behavior remain untested.
Start with the arm-fit test.
The two-key coupon and keeper take an estimated 13.92 g and 39 minutes in Orca. Test them directly on the printed right arm before making the complete bars.
The complete four-part plate is 59.21 g and about 2 hours 14 minutes. Keep the supplied orientation and inspect the slice for your actual ASA spool.
Open the printing steps ↗REV H / THE BRIDGE CORRECTIONRead the path audit ↗
Cross the slots.
Automatic bridge direction ran lengthwise along the long dovetail slots. In the supplied orientation, set both bridge directions to 180°, with Relative bridge angle and Align infill direction to model off. The corrected left and right slices have a maximum unsupported span of 5.19 mm and no disconnected floating components in the deposited-path screen.
This verifies geometric toolpaths, not ASA bridge quality. Download all 14 oriented STEP files, corrected settings and Orca previews ↓
05 / BACK TO THE P1SSix revised parts.
Six revised parts.
Already oriented.
Closed STL meshes, placed for the documented print orientation. Checked against the 256 mm bed, an 8 mm brim and the cutter exclusion.
P1SASA0.4 mm nozzle0.20 mm layersSupports off
The printed arms are not replaced. Original caps and pins remain unchanged. These six files supersede the corresponding older parts in print_ready/.
Get the current D4 / T3 / R2 FreeCAD model ↗
Download the review notes ↓