All dimensions use mm. Tray volume = outer width × depth × floor + wall-ring area × (height − floor). Insert volume = two full-width rails + the crossbars between them. Shared-volume overlap is removed before STL triangulation.
Mass (g) = solid volume (mm³) ÷ 1,000 × assumed density (1.24 g/cm³). Gross feedstock = mass ÷ 0.92. This is a solid geometry model, not a slicer/infill/support estimate. STL volumes are checked against those formulas.
Modeled bench effort = 300 fixed seconds + 20 seconds per bay + 45 seconds for a card/token review. It includes assembly, handling, and inspection, excludes fabrication/postprocessing, and is not time-study evidence.
Synthetic unit USD = gross feedstock kg × $24 + bench hours × $22 + $0.35 packaging + $1.10 overhead. Twenty-kit totals are rounded after aggregation; $7.61 × 20 is not the unrounded baseline batch result of $152.13. Density/price/yield sensitivity is in every review JSON.
Read the method, tolerances, attribution and reproduction steps ↗