PC housings are prone to thermal expansion under prolonged operation. The original 0.2 mm assembly tolerance often produced visible step-gaps in mass production.
- Recessed reveal: A deliberate 0.15 mm recessed groove was designed at material junctions — stacked on top of the existing 0.2 mm tolerance — hiding mechanical variation in shadow so that thermal deformation never becomes visible.
- Rubber base: A full-footprint rubber base absorbs the shear stress of cable plugging, preventing the console from sliding or lifting on the desk.
The key lesson from this project: production tolerance control must always be layered with material behavior (thermal expansion, stress) — never rely on assembly theory alone.