Exactly two enclosure build123d assets and two independently toggleable model nodes. Both nodes now read back at (0, 0, 0), rotation 0, scale 1, Z-up.
Board containment and Z datum
PASS
100 × 60 × 1.30 mm PCB occupies z=0…-1.30 mm; cavity spans z=-5.30…19.00 mm; floor outer face is z=-8.50 mm.
Top controls
PASS after correction, with first-fit checks
VR1/VR2/VR3 use drawing-based interaction-axis offsets transformed through current element rotations. Independent review found S1 was 4.0 mm low in Y; its opening and reinforcement now align with the FS5700 terminal-row center and placed 3D-model offset. D1 is on the top panel at its symmetric lead/model optical axis. LED1 is unchanged.
Wall interfaces
PASS with first-fit checks
J1 now has a rounded rectangular opening for the PJ-037AH 8.9 × 10.9 mm front housing rather than a circular aperture. CN1/CN2 are unchanged. The former rear D1 bore is absent and restored as wall material.
PCB supports
PASS after correction
H1 is confirmed to be a live 1×3 electrical header, not a mounting hole, and is no longer used as a support. H2–H5 are true 2.2 mm NPTH mechanical holes and receive reduced Ø5.0 mm annular supports with Ø2.4 mm relief.
M3 insert bosses and panel holes
PASS after correction
Four boss/hole axes align. Boss OD 9.0 mm, bore Ø4.2 × 7.0 mm, lid clearance Ø3.4, counterbore Ø6.5 × 1.8 mm. Edge pads leave 1.25 mm radial material around counterbores.
PETG / 0.4 mm nozzle DFM
PASS for prototype
Nominal walls/floor/panel are 3.2 mm; local jack panels are 3.0 mm. Registration has 0.35 mm per-side fit. Footswitch zone has a 6.2 mm total reinforced section plus two 2.4 mm ribs.
Connected solids / geometry health
PASS
Pipeline reports one connected solid per asset, with no sliver, floating-solid, or thin-feature finding. Expected down-facing faces remain and are covered by the print-orientation guidance.
Document-to-geometry consistency
PASS after update
Dimensions, corrected S1 center, geometry report, and current durable asset links below match the re-uploaded sources.
Direct scene-tree verification after the read-back discrepancy fix: body model node (0,0,0); top model node (0,0,0); both have rotation 0, scale 1, and Z-up enabled. No node-level registration offset is used.
Corrections made by this review
Final VR/J1 alignment correction
The attached RK09D 3D model node is positioned locally at (2.489, 7.0016, 6.9148) mm. Applying the exact element rotation 90.000210459° gives a visible-shaft XY offset of (-7.001609, +2.488974) mm, replacing the earlier drawing-derived offset (-5.5,+2.5) mm.
Table
Opening
Previous center
Final center
Delta
Size
VR1
(4.372500, 18.300000)
(2.870891, 18.288974)
(-1.501609, -0.011026)
Ø6.6 mm
VR2
(4.372500, -21.220000)
(2.870891, -21.231026)
(-1.501609, -0.011026)
Ø6.6 mm
VR3
(-21.345500, -0.060000)
(-22.847109, -0.071026)
(-1.501609, -0.011026)
Ø6.6 mm
J1
Wall Y=0, Z=6.50
Wall Y=0, Z=5.45
Z=-1.05 mm
9.7 × 11.7 mm, R1.0 mm
J1's placed model has zero local translation. The PJ-037AH front housing is 8.9 × 10.9 mm and spans z=0…10.9 mm from its PCB seating plane, so the housing-clearance rectangle is centered at z=5.45 mm; the existing profile retains 0.4 mm PETG clearance per side.
Source-scope audit: the body geometry changed only in J1_CENTER_Z (6.50 → 5.45 mm). The top geometry changed only in the three VR center tuples. S1 (39.9735,1.7060,Ø12.6), D1 (44.4308,20.0817,Ø4.6), LED1 (-35.2174,-0.0777,Ø5.6), CN1/CN2, dimensions, registration, supports, bosses, reinforcement/ribs, fasteners, color, and material are unchanged.
Opening-alignment revision
Independent re-review found one remaining opening defect: S1 had been referenced to an end terminal instead of the center of its 0/4/8 mm terminal row. The corrected local bushing axis is (2.5, 4.0) mm, consistent with the placed 3D-model offset (2.4653, 4.0366) mm. The project part's attached datasheet is unrelated to FS5700; the official E-Switch FS5700 drawing/manufacturer page was used instead, and the library issue was reported.
Replaced J1's Ø7.2 mm circular wall bore with a 9.7 × 11.7 mm rounded rectangle, R1.0 mm, centered at wall coordinates Y=0, Z=6.5 mm. The PJ-037AH datasheet gives an 8.9 × 10.9 mm front housing and 6.5 mm mating-axis height; the opening adds 0.4 mm PETG clearance per side.
Removed the old D1 rear-wall Ø4.0 mm sight bore. The body source now performs no D1 wall subtraction, restoring continuous right/rear wall material.
Added current D1 (204-10SDRD/S530-A3/F182-68, 4.0 mm body family) to the top panel at (44.4308, 20.0817) mm, with a Ø4.6 mm opening.
Corrected the three RK09D shaft centers using the datasheet shaft axis local coordinate (2.5, 5.5) mm, not the footprint-body bounding-box center. After each +90° element rotation, the local axis becomes (-5.5, +2.5) mm in world coordinates.
Corrected S1 using the FS5700 bushing/actuator axis local coordinate (+2.5, +4.0) mm, centered on the three-terminal 0/4/8 mm row and cross-checked against the placed 3D-model offset. The M12 × 0.75 bushing uses a Ø12.6 mm printed opening; the official recommended panel cutout is Ø12.2 mm, leaving 0.2 mm radial print clearance.
Moved the S1 underside reinforcement and ribs with the corrected switch axis. LED1 and both audio-jack openings were intentionally unchanged.
Old → new opening table
Table
Feature
Previous center / opening
Corrected center / opening
J1
Wall Y=0, Z=6.50, Ø7.2 mm
Wall Y=0, Z=6.50, 9.7 × 11.7 mm, R1.0
VR1
(4.3725, 26.2980), Ø6.6
(4.3725, 18.3000), Ø6.6
VR2
(4.3725, -13.2220), Ø6.6
(4.3725, -21.2200), Ø6.6
VR3
(-21.3455, 7.9380), Ø6.6
(-21.3455, -0.0600), Ø6.6
S1
(39.9735, -2.2940), Ø12.6
(39.9735, 1.7060), Ø12.6
D1
Rear wall Y=-9.6272, Z=3.50, Ø4.0
Top (44.4308, 20.0817), Ø4.6
LED1
(-35.2174, -0.0777), Ø5.6
Unchanged
Repositioned both enclosure model nodes from incorrect offsets to their shared PCB-centered (0,0,0) datum. The top had been displaced far from the board; the body was also offset enough to compromise the S1-side cavity clearance.
Removed the H1 cradle. H1 is PZ254V-11-03P, a powered/programming 1×3 through-hole header connected to +5 V, GND, and UPDI, so it is not a valid mechanical mounting location.
Retained only H2–H5 supports and reduced their contact diameter from 6.8 mm to 5.0 mm to limit underside contact around the true NPTH locations.
Moved the two left closure-boss axes from x=0 to x=-52 mm; the former Ø9 mm bosses overlapped the 100 × 60 mm PCB edge by 1.5 mm.
Added fused Ø9 mm pads around all four top-panel fastener locations. This prevents the Ø6.5 mm counterbores from leaving sub-minimum edge material.
Removed a later -0.6854 mm X offset from the top model node. Source inspection confirmed that body and top already share the same board frame (OUT_CX=8 mm, identical closure axes, and matching registration geometry), so the offset was an invalid hidden placement fudge.
Assets
3D Model
3D Model
Each model card provides the source plus derived STL, 3MF, STEP, OBJ, and GLB downloads.
Authored dimensions
PCB datum: 100 × 60 × 1.30 mm, centered at (0,0), top face z=0.
Assembled maximum envelope: 126.5 × 75 × 31.1 mm.
Main nominal shell outline: 124 × 74 mm, centered at x=8 mm, y=0 to contain the S1 overhang.
Cavity: 117.6 × 67.6 mm, x=-50.8…66.8, y=-33.8…33.8, z=-5.30…19.00 mm.
Nominal wall/floor/top panel: 3.2 mm; recessed jack panels: 3.0 mm.
Floor: inner face z=-5.30 mm; outer face z=-8.50 mm.
Seam: body wall top z=19.00 mm; top-panel underside z=19.40 mm; top face z=22.60 mm.
Registration: 1.2 mm high × 1.2 mm thick tongue; 1.9 mm wide × 0.9 mm deep groove; 0.35 mm per-side PETG clearance.
Registration alignment: body tongue and top groove are both centered at source-frame x=8 mm, y=0; with both model nodes at (0,0,0), their XY centerlines coincide exactly.
Outer corner radius: 5 mm.
Color/material tag: black plastic #1c1c1c.
Top-panel cutouts
Table
Feature
Center X, Y (mm)
Cutout
VR1
2.870891, 18.288974
Ø6.6 mm
VR2
2.870891, -21.231026
Ø6.6 mm
VR3
-22.847109, -0.071026
Ø6.6 mm
S1
39.9735, 1.7060
Ø12.6 mm
LED1
-35.2174, -0.0777
Ø5.6 mm
D1
44.4308, 20.0817
Ø4.6 mm
The S1 region has an underside annulus plus two fused 2.4 mm ribs. CAD verifies attachment and thickness; the first print must still validate stiffness, PETG creep, switch travel, and nut/washer seating under repeated foot load.
Wall cutouts
Table
Feature
Face / axis
Center coordinates (mm)
Cutout
J1
−X / front
Y=0, Z=5.45
9.7 × 11.7 mm rounded rectangle, R1.0 mm
CN1
+Y side
X=-32.0458, Z=8.20
Ø12.0 mm
CN2
−Y side
X=-32.0458, Z=8.20
Ø12.0 mm
CN1/CN2 use fused 3.0 mm recessed panels and are unchanged. J1 clears the actual PJ-037AH rectangular front housing, while its circular Ø6.5 mating aperture remains inside the connector. The previous rear-wall D1 opening is fully removed.
PCB supports
Standoff tops meet the PCB underside at z=-1.30 mm; support height above the inner floor is 4.0 mm.
Table
Ref
X, Y (mm)
Geometry / status
H1
43.3856, -19.1401
No support — electrical 1×3 header, not mechanical. Header pins have approximately 1 mm nominal clearance above the floor based on the 4 mm under-board gap; verify trimmed lead length.
H2
-46.2540, 27.0335
Ø5.0 mm annular support, Ø2.4 mm relief
H3
47.1700, 26.0000
Ø5.0 mm annular support, Ø2.4 mm relief
H4
-46.5390, -26.0500
Ø5.0 mm annular support, Ø2.4 mm relief
H5
47.0000, -26.0000
Ø5.0 mm annular support, Ø2.4 mm relief
H2–H5 align to actual 2.2 mm NPTH footprints. Their reduced 2.5 mm support radius limits contact to the immediate mechanical-hole region; inspect the first bare PCB underside before final assembly for solder-mask damage, protruding hardware, or unexpected copper exposure.
Closure bosses and fasteners
Boss centers: (-52, 33), (60, 33), (-52, -33), (60, -33) mm.
Boss OD: 9.0 mm; insert bore: Ø4.2 mm; bore engagement depth: 7.0 mm.
Top holes: Ø3.4 mm M3 clearance; Ø6.5 × 1.8 mm counterbores.
Fused lid pads: Ø9.0 mm, leaving 1.25 mm radial material around each counterbore.
Insert interference is 0.2–0.4 mm per side for that suggested insert range; confirm against the purchased insert manufacturer's pilot-hole recommendation.
Top: 6 down-facing planar faces totaling 8,673.0633 mm²; this largely reflects the broad underside when evaluated in authored orientation.
All connector, insert, clearance, and counterbore cuts occur after unions, so their modeled axes are unobstructed.
One-solid reports confirm bosses, pads, supports, ribs, and registration features are fused into their parent parts rather than merely touching as detached bodies.
Suggested PETG FDM settings
0.4 mm nozzle; 0.20 mm layer height; dry PETG.
6–8 perimeters; at least 6 top/bottom layers; 30–40% gyroid infill.
Body: print floor-down. Use localized/tree supports for horizontal connector bores and jack-panel recess overhangs.
Top: preferred orientation is cosmetic top face on the build plate (flip the authored model in the slicer), so the underside ribs build upward without supporting the broad panel. Accept the build-plate texture on the exterior. If printing underside-down, support the broad panel and counterbore regions and expect more cleanup.
Use a 5–8 mm brim on the body if corner lift occurs.
Install inserts square and stop flush; use the lowest practical iron temperature and dwell that fully seats the insert without softening the boss.
Assembly
Print both parts and clear all support material from connector bores, the groove, insert bores, and counterbores.
Test each M3 insert in a sacrificial PETG coupon using the same Ø4.2 mm pilot before installing the enclosure inserts.
Inspect the PCB underside at H2–H5 and trim H1/other through-hole leads if needed; maintain clearance above the floor.
Heat-set four inserts into the body bosses.
Lower the PCB onto H2–H5 and confirm it seats flat without rocking; H1 must remain free and non-contacting.
Engage J1, CN1, CN2, and D1 with their openings and fit supplied nuts/washers where applicable.
Pass VR1–VR3 shafts, S1 actuator/bushing, and LED1 lens/light path through their panel openings.
Engage the registration tongue/groove and install four M3×8 screws evenly, only until the seam closes.
Assumptions requiring first physical fit test
Potentiometer Ø6.6 mm holes provide 0.3 mm radial clearance around the documented Ø6 mm shafts. These RK09D variants have a sleeve/collar rather than a documented threaded panel bushing; knob base and collar seating remain physical checks.
S1 uses the official FS5700 M12 × 0.75 bushing, Ø10 actuator, 2.7 mm travel, and Ø12.6 printed opening around the independently corrected axis (39.9735, 1.7060). Confirm washer/nut stack, panel seating, and full travel through the 3.2 mm panel on the first print.
LED1 may not protrude to the top surface at the 19.4 mm panel datum. Verify lens visibility and decide whether the assembled pedal needs a press-fit light pipe or an integrated transparent insert in a later revision.
D1 is a current 4.0 mm-body LED centered at the midpoint of its symmetric 2.5 mm-pitch leads and the model XY origin. The exact lens/flange maximum and protrusion at the 19.4 mm panel datum were not recoverable from OCR/model metadata; verify the Ø4.6 mm opening and visible projection with the installed part.
Verify CN1/CN2 rear-mount nut/washer engagement through the 3.0 mm local panels and check plug insertion/withdrawal clearance with real 1/4-inch plugs.
Verify PJ-037AH plug overmold and full 9.8 mm insertion against the 9.7 × 11.7 mm rectangular opening. Housing clearance is centered at Z=5.45 mm; the circular mating axis remains at Z=6.5 mm inside the rectangle. The user's exact cable overmold is not project data.
Four-point H2–H5 support is geometrically aligned, but the board is not independently screwed to those supports in this two-part design; the panel-mounted controls/connectors and closed lid provide assembly retention. Confirm no rattle under pedal impact.
PETG footswitch stiffness, boss pullout strength, insert torque, registration fit, and print shrink vary by printer and filament and require a first article before production use.