ROLLER STUDIO — PROTOTYPE 0.4 — INCH WIDTHS, STL COORDINATES IN MILLIMETERS

Use the new rigid core that matches BOTH your handle width (1.5 / 3 / 4.5 inches = 38.1 / 76.2 / 114.3 mm) and selected diameter profile (Original or Larger). Larger files contain roomy in their names. Larger sleeves do not fit Original cores.
The TPU sleeve does NOT go over the original textured barrel. Do not scale any STL.

FIRST: FIT TRIALS
1. Print fit-core.stl in your intended rigid material (PLA or PETG is a trial assumption).
2. Print the three named fit-sleeve files in your intended TPU. Start with 95A as an assumption, not a tested material specification. Keep each trial's name with it.
3. Align the three flats; stretch/slide the sleeve onto the 10 mm test core until its internal bead seats in the groove. Check twisting under hand torque, axial creep and ease of removal. Test wet as well as dry. Select Snug / Line-to-line / Loose in the webpage according to the actual result.
4. Reuse the existing bearing-v07 bearing-fit coupon process. Seat diameter22.2 mm remains nominal; no bearing fit has been proven by this prototype. If actual bearing coupons require another seat diameter, adjust mechanical/core.py and regenerate; do not change global scale.
5. A short test does not prove that a full 4.5-inch sleeve will install or stay in place. Begin with one full medium sleeve after small fit trials pass.

PRINTING
- Sleeve: axis upright, flat annular end on bed. The hole stays open. Start with your printer/filament manufacturer's TPU profile and dry filament as instructed for that material. Use slicer preview to ensure the ~1.9 mm base wall has continuous bonded paths (no sparse gap through the shell). A0.4 mm nozzle and0.16–0.20 mm layer height are trial assumptions, not validated settings. Relief is capped at1.2 mm for the Original profile and2.0 mm for Larger.
- Rigid core: axis upright; inspect the lower internal counterbore and bearing shoulder bridges in the slicer. Avoid trapped support in the bore. Starting trial:4 walls,5 top/bottom layers,20–30% infill, subject to slicer preview and fit testing.
- Fine artwork can disappear. The mesh is sampled at0.25 mm, not a guaranteed0.25 mm printable feature. Aim initially for marks at least0.8 mm wide and inspect each sliced texture. Steep relief can need additional smoothing or reduced depth. The software's feature and overhang warnings are screening only.
- The app's smooth seam band removes sharp artwork discontinuities. It still produces a visible plain strip if the image is not seamless. 'Keep artwork' closes the mesh but cannot make mismatched art seamless.

ASSEMBLY
1. For a first complete tool, print the NEW matching inch-width handle plus the unchanged v0.7 grip/covers/spacers and use the specified hardware, substituting this new core and sleeve for the old textured barrel. Legacy 36/72/108 mm handles and axles are NOT the correct width for these inch-size sleeves.
2. With the new core out of the handle, align the sleeve's three flats, ease it over the core, and seat both end beads in the grooves. Do not use the bearings as a press tool. TPU installation and retention are not yet validated.
3. Seat the two608 bearings against the shoulders10.2 mm below each end. Press on outer rings only. Outer bearing faces remain3.2 mm recessed. Refit splash covers and inner-ring spacers following bearing-v07 instructions.
4. Fit the barrel into the matching handle. Use 8 mm diameter axles cut to 76.1 / 114.2 / 152.3 mm for 1.5 / 3 / 4.5-inch rollers, respectively. Axle length is roller width + 38 mm. Collar-to-fork spacing remains1 mm and the axle has3 mm exposed beyond each6 mm collar. Do not use collars to squeeze the bearings.
5. Confirm free rotation at both axial extremes and under gentle clay pressure. Check no TPU end bulge contacts the fork. Confirm neither twisting nor sleeve creep. Roll the provided orientation-F artwork to verify text direction before using important artwork.

CLEANING / LIMITS
Remove the axle and barrel to replace sleeves. Peel/slide sleeves off gently; do not force sharp tools between sleeve and core. Rinse clay off TPU, wipe bearing faces, and dry hardware promptly. Do not soak the assembly. The existing splash covers are not waterproof seals.

This is a CAD- and mesh-checked prototype, not a completed print trial. Verify bearing fit, full sleeve fit, retention, torque transfer, clay release, detail, durability and cleanability physically. A photograph becomes a2.5D brightness map; the app does not recover sculptural anatomy or commercial tooling detail.

LEGACY FILES
Previously generated 36 / 72 / 108 mm rollers remain legacy sizes; use their original handles and 74 / 110 / 146 mm axles. Do not mix legacy and inch-width parts. Cross-sectional fit kits still apply to both width families.