Mass Target Revision
The original ~250 g aluminum target was mathematically unreachable inside the approved envelope. The target was revised to 205–220 g and formally replaced, not quietly kept.
Early in the program, 250 grams was written down as the aluminum assembly target. When the approved exterior envelope was modeled honestly — Ø50 crown, Ø30 neck, real wall thicknesses — the math didn't reach it. Aluminum simply doesn't have the density to hit 250 g in this volume without violating the geometry.
There were two options: keep an aspirational number that the part could never meet, or replace it with one the geometry supports. The target became 205–220 g. The current Rev A assembly calculates to 218.2 g — near the top of the band, achieved with real geometry rather than wishful specification.
Mass that wants to be higher belongs to different materials. That's what the titanium and brass variants are for.
Technical Notes
- Rejected: 250 g aluminum assembly target.
- Approved: 205–220 g aluminum assembly target band.
- Current calculation: 218.2 g with 6061-T6 body and ~35 g steel insert.
Decisions Made
- Targets that contradict the geometry are replaced, not preserved as marketing numbers.
Next Validation Step
Validate the mass balance band against the revised target.