# MORLOK PF1 printed frame and plate plan

**Unqualified candidate for review. No printer send, approved toolpath, payload rating or completed print is included.**

The requested frame is printed; there is no metal structural deck. This first stationary candidate adds 19 pieces to the unchanged 37-piece BC1 enclosure. Electronics, camera, speaker, fasteners and eventual drive hardware remain purchased items.

## How many times do I print?

The planned Creator 5 Pro layout has **20 runs on the same reusable build plate**:

- 2 fit-test runs: T1 camera/shutter in the selected PLA trial material; T2 frame-joint and interface samples in the candidate PETG
- 5 new-frame runs: F01–F05
- 13 body runs: B01–B12 plus BP, the separate four-tall-post plate

The main 18 runs contain **56 pieces**, not 56 separate jobs: 19 new frame pieces and 37 existing body pieces. The 2 test runs contain 12 additional specimens. The frame/body set is stationary; final case restraints, cable fittings and mobility mounts can add pieces and runs later.

This count assumes every test passes and no replacement is needed. It is not a minimum packing count. Layouts reserve 8 mm brim space around each object, at least 5 mm at the plate boundary and 2 mm between reserved envelopes on a nominal 256 × 256 mm bed. Real profile keep-outs, supports, brim choices or failed tests may change it. Do not shrink parts to preserve a count.

**No time or filament estimate is available:** these files have not been sliced in the actual Creator 5 Pro profile. All 3MF files are geometry only, with no G-code, printer connection, material/tool routing or temperatures.

## Current frame pieces

| ID | Piece | Installed quantity |
| --- | --- | ---: |
| F01 | Front-left ribbed base quarter | 1 |
| F02 | Front-right ribbed base quarter | 1 |
| F03 | Rear-left ribbed base quarter | 1 |
| F04 | Rear-right ribbed base quarter | 1 |
| F05 | Under-seam overlapping splice | 4 |
| F06 | Front/rear crossmember | 2 |
| F07 | Slotted removable equipment tray | 1 |
| F08 | Tray riser | 4 |
| F09 | Stationary foot | 4 |
| Total | New printed frame candidate | 19 |

FT01 and FT02 are source-derived joint sample halves, with an extra F05 brace on the test plate. They are not installed pieces. **Part IDs and plate IDs are different:** for example, part F01_base_front_left is on frame plate F02. Always follow the complete filename and the numbered run list.

## What is still missing

- Actual CanaKit case/cooler dimensions and secure retention. The 180 × 140 mm default tray is a project-selected envelope with slots, not proof of fit and not permission to leave a loose powered kit on it
- Actual plug bends, cable pass-through/edge protection/strain relief and service clearances
- Received Lite revision/hole layout, camera optics, shutter opacity, speaker clearance and closed-body acoustic/thermal results
- Real screw/nut/head dimensions and clamping stacks. Candidate M4 clearance is 4.4 mm; nut pockets are project-selected 7.5 mm across flats and 3.5 mm deep and must be tested with actual hardware
- Strength, deflection, creep, layer-direction and temperature qualification for the actual PETG and printer profile
- Motor, wheel, caster, battery and independent drive-stop mounts; no powered mobility release

## Candidate assembly logic after measurements and test acceptance

1. Identify the four handed base quarters using their full filenames. Keep the 0.4 mm central seams; do not force the joint closed.
2. Bridge the four half-seams using four F05 splices underneath. Printed nut pockets face up on the bed but down in assembly. Insert and retain actual qualified nuts before the joint is inaccessible.
3. Put the front/rear F06 crossmembers on the upper rib plane. The four F09 feet sit below their attachment axes, using the same nominal through-bolt stacks. This gives a 220 × 164 mm foot-centre rectangle; stability is still unqualified.
4. Fit four F08 tray risers and the F07 tray. Preserve slot, cable and tool access. Final case restraints require the kit measurements before powered use.
5. Review the old shell’s four base attachment points against the candidate ±129/±99 mm axes and actual screws. The original shell geometry is unchanged, translated up 11 mm in the inspection assembly to meet the new rib plane. This is a digital alignment reference, not a proven fastener interface.
6. Assemble walls, joiners, lid and PC1 modules using the individual parts index and original fit gates. The microphone bridge is not a lifting handle.

The candidate uses 24 nominal M4 through-bolt positions: 16 splice positions, 4 shared crossmember/foot positions and 4 tray-riser positions. The four shell-base M3 positions belong to the preserved shell count. **These are interface-position counts, not a released shopping list.** Actual lengths, washers, nut fit, engagement, head clearance and access must be measured.

## Before any real print

- Check the current printer is idle, its bed is clear and no prior job or transfer is pending
- Verify exact printer/nozzle, actual filament type/reel, material compatibility and explicit material-to-tool assignment
- Keep original geometry at 100% millimetre scale; use the supplied bed orientation unless a reviewed change is recorded
- Inspect each sliced layer, support/brim effects and tool clearance. Tall posts have their own plate; never silently switch to sequential by-object printing
- T1/T2 results must be recorded before any main batch. Prior PLA prints do not qualify PETG joints or a complete frame
- Compare actual parts and file revisions before reusing or crediting an older test; never automatically resend a job because the printer returned to Idle

## Digital verification

All 11 new STL types passed closed-edge, winding, single-component, nondegenerate-face, positive-volume and Z=0 checks. The 19 frame solids are valid single solids and their scoped assembled solid intersections are zero. All 20 geometry-only 3MFs were read back in lib3mf strict mode with zero warnings and the expected build-object counts. Plate allocations are inside the nominal bed and their reserved rectangles do not intersect.

These checks exclude real hardware, screw stacks, cables, strength, process settings and physical behavior. Neither a watertight mesh nor a 3MF file certifies a safe printed chassis.

## Files and rebuilding

- `cad/build_frame.py`: editable CadQuery source; change the project-selected parameters in a new dated copy and regenerate
- `parameters.json`: recorded defaults used for this candidate, not measured hardware
- `stl_CANDIDATE_HOLD/`: individual new frame and joint-test STLs, already normalized to the bed
- `step/`: individual editable solids; `PF1_Frame_Assembly_CANDIDATE.step` is an inspection assembly, never a one-piece print
- `PF1_Printed_Frame_With_BC1_HOLD.blend`: 56 separate printed meshes, no metal deck or invented hardware
- `plates/`: 20 independent geometry-only 3MF plate files
- `plate_plan.json`: object placement, quantities, original hashes, materials, run numbers and explicit unknowns
- `preserved_BC1/`: unchanged old STL files and manifest, kept separately
- `qa/`: scoped digital test records; no physical pass claims

Requires CadQuery 2.7/OpenCascade, NumPy, Matplotlib, Pillow, lib3mf and Blender. Run build_frame.py, verify_meshes.py, plan_plates.py, render_frame.py and then create_blender_scene.py in a copied package. Rebuilding can overwrite generated candidate files within that copy. No script dispatches a printer or contacts one.