Kraken ASA bodies and front bars — 2026-10-16

RECOMMENDATION
Ready for a first full-size ASA print and fitting. Use the supplied left and
right plates, each containing its body and matching front bar. The isolated v4
underside revision removes the problematic long unsupported ledges; accepted
mechanical interfaces and the original accepted release are preserved.
No body or coupon job has been sent. Confirm the loaded ASA slot and clear plate
with the operator before submission. The saved filament color is only a swatch.

FILES AND ESTIMATES
left/kraken-left-asa.3mf: 12h44m12s, 281.63 g.
right/kraken-right-asa.3mf: 12h47m14s, 280.78 g.
fit-check/kraken-asa-alignment-check.3mf: 51m44s, four 84 mm pitch coupons.
Times and masses are Orca estimates, not measured print results.
Projects contain sliced G-code plus editable body modifiers. Print the supplied
slice; if changing or reslicing it, repeat the relevant checks. Open the two body
projects separately. Their 244.9 mm height requires the supplied upright pose.

RECIPE
Printer: Bambu P1S, 0.4 mm hardened steel, Standard nozzle designation.
Slicer: local native OrcaSlicer 2.5.0-dev with retraction-frequency protection.
Material: Polymaker ASA, flow ratio 0.95, maximum volumetric flow 12 mm3/s.
Nozzle 260 C; textured plate 95 C; startup includes a 10 minute heat soak.
First layer and subsequent layers: 0.20 mm.
Bodies: 2 walls, 15% rectilinear; dense root masks 4 walls/100%; wall-path
masks 4 walls/15%. Dense masks have precedence over overlapping wall masks.
Front bars: uniform 4 walls/30% rectilinear; no modifiers.
Five top layers, four bottom layers; monotonic top surfaces; scarf disabled.
Body brim: outer only, 8 mm, 0.15 mm separation. Bars: no brim.
Supports and prime tower disabled; single material, no in-print color change.
Print/travel acceleration cap 5000 mm/s2; first layer 500; top surfaces 2000.
Normal ASA retraction 0.8 mm. Guard: soft count 3 per 1 mm fresh filament;
hard minimum 0.3 mm fresh extrusion between normal cycles. Startup/unload/end
routines are retained. The 0.3 mm threshold is not the retract distance.
Normal part cooling 0–20%, overhang cooling 30%; aux and chamber exhaust off
during deposition. Chamber exhaust at 30% in the end routine.
XY shrink 100%, hole compensation 0, contour compensation 0. No global scaling
was inferred from a single hole fit. Exact editable profiles accompany the jobs.
The recipe has been reopened with CLI guard defaults disabled: stored values
remain intact. Orca duplicates four hotend metadata vectors with identical
values on reopen; the comparison records those differences explicitly.

STRUCTURE AND COMPATIBILITY
The independent net-section screen covers two spools up to 2 kg per half, 2g
gravity allowance and a 75/25 end-load bias. Peak nominal demands were 1.20 MPa
for shaft strips and 2.16 MPa for roller strips. This supports targeted dense
roots rather than blanket solid fill. Those native load strips and all four
reinforcement masks remain unchanged in v4.
Whole-body FEA was unconverged. Its relative stiffness results are not physical
predictions or a safety factor. This recommendation is for ordinary indoor,
unheated AMS use. Long-term creep, screw preload and full-box fit are untested.
Front bars use the simpler 4-wall/30% reference recipe selected by the structural
review. Detailed assumptions and limits are in evidence/engineering.
Native hardware-contact checks pass 109/109 right and 101/101 left at the 0.05 mm
scope. RFID no-addition, installation, routing, cut5 joints, locating surfaces,
export integrity and mask containment checks pass. The source-matched 0.65 mm
roller blind stop is retained. Sampled ordinary continuous walls exceed 1 mm.
The original accepted bodies/bars and manifests were verified unchanged.

PRINTABILITY EVIDENCE
Both final plate projects preserve oriented mesh triangles, modifier placement,
object settings, shared transforms and X-axis key pitch after reopening.
Both fit inside the bed without rotating the bodies or bars. First-layer checks
show no flagged small contact islands or exclusion-zone conflicts. Preview
images show the body brims and separated front bars.
The final straight bridge screens contain 2091 left / 2081 right segments.
Largest geometric free interval is 5.95 mm, with material at both endpoints.
Nine right bridge arcs are excluded from that straight-span calculation; arcs
are included in the separate void/centerline check. Short single-ended segments
up to about 2.45 mm are inside earlier same-layer wall paths. Their surrounding
wall paths span the opening; layer/order evidence is included. This is an
engineering acceptance for a first print, not measured ASA bridge performance.
Full-height geometry has no new floating starts relative to the accepted bodies.
Remaining tiny starts belong to existing board-retainer/post details.
The combined-plate gross-void screen checks 1,711,071 left and 1,755,417 right
points, including arc samples: zero outside the nominal section plus 0.05 mm
centerline allowance. Horizontal-plane numerical boundaries were resolved with
an explicitly recorded +/-0.0001 mm section neighborhood. This does not test
the entire bead envelope or certify printed clearance.
Guard verification: 24,082 left / 23,861 right normal cycle intervals; minimum
fresh extrusion 0.30003 / 0.30013 mm. Coupon minimum 0.34043 mm. No violations.
Actual deposition temperature, cooling, acceleration and flow checks pass.
Raw flow ratios on extremely short serialized moves include rounding error;
the long-move and quantization-bound checks are recorded separately.

ASA ADHESION AND WARP
Use the established enclosed ASA setup, clean textured plate, heat soak and
stable surroundings. Avoid drafts. Let the complete plate cool naturally in
the enclosure before removal. The 8 mm brim helps adhesion but cannot guarantee
that a 245 mm tall body or its locating lands stay straight.
Do not use screws to pull a bowed part into shape. Do not boil or anneal these
dimension-sensitive parts as an uncalibrated repair. Inspect cooled flatness
and fit first; any corrective shrink or geometry change needs new measurements.

PHYSICAL ACCEPTANCE
1. Print the small 84 mm paired-key coupon plate in the intended ASA/profile
   first where practical. Both keys must enter together and both zero-gap tapers
   must seat by hand with shoulders flush. Keys have 4 walls/100%; sockets 4/30.
   Pitch is along X, matching the final bodies and bars. The coupons do not
   reproduce full-height warping, full-box retention, or every layer phase.
2. Fully cool the bodies and bars. Inspect for lifting, cracks, displaced feet,
   distorted seating lands, rough socket mouths and sagged roofs. Clear loose
   strings only; do not force hardware through the thin roller blind stops.
3. Dry-fit halves, hardware and routed cables with bars absent. Set the assembly
   loosely into the box, seat both bars fully, then engage tabs and fasteners.
   Screws must start normally and shoulders must meet without forced bending.
4. Confirm cable slack, connector access and PTFE routing. Actual flexible cable
   bundle dimensions and a complete AMS box solid were unavailable; test these
   physically before final tightening.
5. Add the intended spools progressively. Rotate and feed in every bay; verify
   no rubbing, seat movement, cable trapping or incomplete bar capture. Recheck
   seating and permanent movement after 24 hours under intended service load.
   Carry a loaded tub by its supported body, not front bars, keys or feeders.

NATIVE 0.05 mm acceptance does not promise 0.05 mm printed accuracy. The above
checks define acceptance of the first print; they are not a lifetime rating.