THE ENGINEERING RECORD, FILE 11 OF 19

Bands, pods, and materials

Every file of the record The engineering hub

Sized for the 5th to 95th percentile adult. ANSUR II and NHANES class references, biased generous because the general population runs larger than the military sample. Bands are breathable elastic webbing with a soft brushed liner and hook and loop plus a cam buckle. Pods are PETG or nylon with a certified skin safe TPU face; textiles in prolonged skin contact meet OEKO-TEX STANDARD 100 Class II; skin contact plastics pass ISO 10993-5 and 10993-10. Source: docs/11.

The belt pod: a rounded box the length of a hand, its three printed bodies lifted apart, the PETG base with sensor windows in its outward face, the PETG lid with two belt slots, and the soft TPU skin plate. Outer dimensions: base 128 by 62 by 28 mm, lid 128 by 62 by 2 mm, skin plate 128 by 62 by 1.6 mm, assembled 128 by 62 by 32.3 mm. — The belt pod, from the OpenSCAD part. The sensor head and the electronics core in one PETG shell with a PETG lid toward the belt and a TPU skin plate against the body. The outward face carries every sensor window: the forward laser grid, the ground grid on a 35 degree wedge, a half wave radome for the radar, 3.6 mm, a design value until measured, and two sonar openings turned 20 degrees outward. Four cable exits with grommet bosses, screw bosses, and a gasket groove to IP54 class. Module outlines inside are working figures to be checked against the parts in hand. Outer dimensions, design values until a printed part is measured: base 128 by 62 by 28 mm, lid 128 by 62 by 2 mm, skin plate 128 by 62 by 1.6 mm, assembled 128 by 62 by 32.3 mm. Strain relief channels and service loops are not yet drawn; every enclosure dimension here is a design choice, not a measurement. Source: hardware/scad/belt-pod.scad, drawn from docs/04, 09, 10, 11.

Blueprint, isometric view of the belt pod with its outer dimensions written under it, design values to be measured on the printed part. — The belt pod, from the OpenSCAD part. The sensor head and the electronics core in one PETG shell with a PETG lid toward the belt and a TPU skin plate against the body. The outward face carries every sensor window: the forward laser grid, the ground grid on a 35 degree wedge, a half wave radome for the radar, 3.6 mm, a design value until measured, and two sonar openings turned 20 degrees outward. Four cable exits with grommet bosses, screw bosses, and a gasket groove to IP54 class. Module outlines inside are working figures to be checked against the parts in hand. Outer dimensions, design values until a printed part is measured: base 128 by 62 by 28 mm, lid 128 by 62 by 2 mm, skin plate 128 by 62 by 1.6 mm, assembled 128 by 62 by 32.3 mm. Strain relief channels and service loops are not yet drawn; every enclosure dimension here is a design choice, not a measurement. Source: hardware/scad/belt-pod.scad, drawn from docs/04, 09, 10, 11.

The motor pod: a small rounded shell for the driver board with two webbing loops, and the soft TPU face with a raised seat for the coin motor, lifted apart. Outer dimensions: shell 34 by 29 by 16.8 mm with its webbing loops, face 34 by 26 by 4.8 mm with its motor seat, assembled 34 by 29 by 18 mm. — The motor pod, from the OpenSCAD part. Twenty per kit. A small PETG shell holds the DRV2605L board and two webbing loops; the TPU face carries the coin LRA in a raised seat so it presses on the skin through the band liner. Motor lead JST SH 2 pin, bus JST SH 4 pin; a pod is a plug replaceable module. Outer dimensions, design values until a printed part is measured: shell 34 by 29 by 16.8 mm with its webbing loops, face 34 by 26 by 4.8 mm with its motor seat, assembled 34 by 29 by 18 mm. Strain relief channels and service loops are not yet drawn; every enclosure dimension here is a design choice, not a measurement. Source: hardware/scad/motor-pod.scad, drawn from docs/02, 03, 10, 11.

Blueprint, isometric view of the motor pod with its outer dimensions written under it, design values to be measured on the printed part. — The motor pod, from the OpenSCAD part. Twenty per kit. A small PETG shell holds the DRV2605L board and two webbing loops; the TPU face carries the coin LRA in a raised seat so it presses on the skin through the band liner. Motor lead JST SH 2 pin, bus JST SH 4 pin; a pod is a plug replaceable module. Outer dimensions, design values until a printed part is measured: shell 34 by 29 by 16.8 mm with its webbing loops, face 34 by 26 by 4.8 mm with its motor seat, assembled 34 by 29 by 18 mm. Strain relief channels and service loops are not yet drawn; every enclosure dimension here is a design choice, not a measurement. Source: hardware/scad/motor-pod.scad, drawn from docs/02, 03, 10, 11.

Sizing for 5th to 95th percentile adults (ANSUR II and NHANES class references; the general population runs larger than the military sample, so bias generous):

Waist: about 70 cm to about 130 cm. Belt sizes S, M, L, XL with 15 to 20 cm of elastic and hook overlap each.
Chest strap: about 80 to 120 cm, two sizes with adjustment.
Neck (collar strip): about 32 to 45 cm, one size with adjustment.
Ankle: about 20 to 28 cm, one size with a wide hook and loop range.

Bands: breathable nylon or polyester elastic webbing, soft brushed skin side liner, hook and loop plus cam buckle closure. Belt and ankles sit on skin or over a thin base layer; the collar sits over a base layer. Attenuation through one thin fabric layer is budgeted and will be measured before any perceptual claim.

Pods: PETG or nylon for structure; TPU 85A to 95A for the skin side face and flex hinges. The skin side face must be a certified skin safe grade (ISO 10993-5 certified PETG or TPE filaments exist); generic flexible filament is not rated for prolonged skin contact.

Named picks for skin contact: Smooth-On Dragon Skin or Ecoflex silicone for overmolds, compliant faces, and pads; Formlabs BioMed resin for printed housings that touch skin; 3M 2477P medical silicone tape for optional pads. Textiles in prolonged skin contact meet OEKO-TEX STANDARD 100 Class II. Skin contact plastics pass ISO 10993-5 (cytotoxicity) and ISO 10993-10 (irritation and sensitization). Bands are removable and hand washable; electronics pods are wiped, not immersed.

Comfort: rounded skin side edges, compliant TPU faces, load spread over wide webbing, battery center back to avoid a front pressure point.

Source: docs/11-bands-pods-materials.md, the engineering record. Every number on this page is read from that file. If a fact is not in the record, it is measured on the bench, or it stays off this site.