Stopped before geometry mutation under the explicit requirement not to guess PCB contact keepouts. No base, lid, plunger, PCB geometry, or existing model-node rules were modified. This report does not qualify any existing support asset as safe.
Scope results
Table
Item
Status
Evidence or blocker
Read actual PCB outline and seating datum
Completed
Live normalized layout_2d outline and stackup inspected; PCB top Z=0, nominal bottom Z=-1.50 mm.
Establish two verified bare left/right contact zones
Failed / blocked
No complete proof of top/bottom copper-free contact strips, including generated GND fill, was obtained.
Establish safe bottom edge support contacts
Failed / blocked
Existing independent-enclosure-base-review already fails electrical-contact safety for prior supports. Current reads do not resolve that finding.
Add integral arms, hooks, root fillets, tabs and ledge
Unattempted
Blocked by the two contact-safety items above.
Calculate actual insertion/release deflection and strain
Unattempted
Exact hook overlap, lateral tolerances and collision-free swept path are not established. Conditional limits below are not a finished clip design.
Compile and upload revised base
Unattempted
No safe geometry authored; no new base URL exists.
Requires a safe authored revision and complete contact/sweep envelopes.
Preserve existing base cutouts, lid and plungers
Completed by non-mutation
No asset or model-node writes performed.
Read close-up 3D view
Completed for existing PCB only
Relay-bank render succeeded; this is not a revised-base fit view.
Verified outline, not safe contact locations
The PCB custom outline is 89 × 99 mm overall, but the relay-side portion is narrower than the bounding rectangle. In PCB-centred, Y-up millimetres:
Left actual side edge: X=-40.728 over Y=17.244…49.500.
Right actual side edge: X varies from +40.700 at Y=17.244 to +40.699 at Y=49.500.
Relay-end edge: Y=49.500.
Do not put relay-side clips at X=±44.5: those are the wider lower-board bounding edges, not the actual side edges in this region.
Recorded enclosure/root transform is (+45,-50,0) mm; contact heights must stay at board bottom Z=-1.50 and hook underside above board top Z=0 with an explicitly selected fit gap.
Precise unresolved evidence
Live scene-tree reads expose a generated GND Fill node 6ca7bb24-5dbe-441d-a8cf-3a297a6b651e.fill, but the returned fill row has no boundary coordinates or layer coverage. Reading persisted polygons is not sufficient: all three returned manual copper polygons are Top-side features elsewhere, and they do not describe the GND fill. Filtered 2D reads also scope away surrounding routing and cannot establish an all-copper exclusion over both side-edge strips. No approved dimensioned contact keepout map or Measurements record resolves this.
Consequently, a gap between a relay body and the board edge, or the nearest visible pad, cannot be called a verified bare PCB contact zone. Solder mask appearance in the render does not prove copper absence. No actual collision is asserted here; the safety proof is missing.
The current task brief refers to the latest approved mockup, but no mockup image is present in the handed-off context. Multiple base support revisions exist in assets; a specific approved revision should be pinned before any later edit rather than selected from filenames alone.
Conditional PETG sizing limits only
Manufacturing requested: PETG FDM, 0.4 mm nozzle; floor-down print orientation, with arm deflection in the XY print plane. Minimum beam thickness 1.2 mm; ordinary free-length minimum 8t=9.6 mm. Nominal approximately 4 mm width, 0.4 mm engagement, 45° lead-in and root fillet ≥1 mm remain requested provisional starting parameters, not generated dimensions.
Using the requested estimate strain = 1.5*t*d/L², for t=1.2 mm:
At L=9.6 mm, a 2% estimate permits d≤1.024 mm.
At L=6.0 mm, a 2% estimate permits d≤0.400 mm. This does not include tolerance or extra release travel and does not meet the normal 8t length rule; no 6 mm beam is approved here.
Required d must include actual lateral hook overlap, board/enclosure dimensional tolerances and clearance needed to fully disengage. The stated 0.4 mm engagement alone is not proof of the required outward travel.
Actual strain, release force, creep and cycle life remain unverified. Dual independent hooks also require a kinematic check against sequential one-side lifting; two tabs by themselves do not prove that simultaneous release is mechanically required.
Evidence needed to resume
Pin the approved base asset revision and provide the approved mockup to the geometry worker.
Provide authoritative top/bottom copper artwork including final generated pours and pad/via geometry, or a verified mechanical keepout map specifying exact permitted side-edge Y intervals and inward contact widths on both PCB surfaces.
Include actual solder/protrusion and connector insertion envelopes where they approach those zones; confirm bottom-ledger strips separately.
Once verified, select the hook overlap/tolerance stack, compute outward deflection, author XY-flexing arms, and compile/upload only the new base. Preserve all opening subtraction geometry and all lid/plunger assets.
The view confirms relay/terminal placement qualitatively, not hidden copper or underside solder clearance. Editor display could not be switched because no requester frontend session was available.