Design Progress | Week 12

Nov 11, 2025
1 min read

Updated: Nov 12, 2025

Dates: 11/05/25 - 11/11/25

This week’s progress involved extensive refinement and troubleshooting of the NAVI headset’s front assembly. During inspection of the latest print, an error was discovered on the front plate—a small gap in the left-center IR sensor mount caused the support material to strip when removed.

After reviewing the CAD model, several loft and extrude modifications were made to strengthen the internal supports for the IR sensors and reduce excessive support filament during printing. M3 screw holes were added to secure the side strap connection points, and 15 mm inserts were implemented on the faceplate to accommodate the power and mode select buttons.

A complex brim geometry was also developed to connect the front and faceplates more effectively, prioritizing assembly access and troubleshooting over aesthetics. The first faceplate print failed overnight due to a support shift, and the second, while successfully printed, had support material stuck in the inlay, preventing full connection with the front plate.

Dremel tools were used to manually test and modify the failed print, cutting precise inserts for the headband to ensure a secure and stable fit.

Additionally, a new battery cover was designed to house the Li-Po battery safely, preventing contact with nearby boards and components—an improvement resulting from collaboration with Anthony. The faceplate was printed on the Creality K1 Max, while the battery cover was produced using the Prusa MK3.

Work has also begun on the final project report, and the weekly time and effort log was corrected a