WORX WG540.5 Detailing Nozzle — V1.2 FIT PROTOTYPE

Why V1.2 exists
- V1.1 fractured during insertion despite a nominally larger bore.
- V1/V1.1 were generated through voxel/marching-cubes meshing, which is not ideal for a tolerance-sensitive mating diameter.
- V1.2 is rebuilt as exact OpenSCAD CSG geometry.

V1.2 changes
- Exact mounting ID: 57.60 mm.
- Sleeve wall increased to 3.40 mm.
- 4 mm lead-in chamfer with only 0.8 mm extra radius at the mouth.
- OEM button opening retained at the V1.1 corrected axial position (26.8 mm from seated edge).
- Molded boss relief retained but given a rounded termination to reduce stress concentration.
- Main nozzle length and airflow flare remain essentially the same as the successful V1 shape.

PRINT THIS ONE IN PLA FIRST AS A FIT TEST.
Do not spend ASA/PETG on it until fit and button alignment are confirmed.

Bambu A1 suggested prototype settings
- Material: PLA
- Layer height: 0.20 mm
- 4–5 walls/perimeters
- 25–35% gyroid/cubic infill
- Do NOT scale the STL
- Mounting end on build plate
- Supports only where slicer indicates around the button opening
- Brim optional

Fit test
1. Make sure the underside boss relief is aligned with the molded boss.
2. Align the top opening with the OEM release button.
3. Slide the nozzle on gently; it should no longer require brute force.
4. Stop if the sleeve visibly spreads or begins to whiten/crack.
5. Confirm it seats to the shoulder and the button rises fully into the opening.
6. Confirm the button releases the nozzle cleanly.

Final material after geometry is verified
- PETG: easiest durable choice on an open-frame Bambu A1.
- ASA: better heat/UV resistance, but harder to print reliably on an open A1.
- Avoid PLA for the final garage/summer-use part.