OK I declare, in the words of Borat, "Great Success"* 🎉 (*with minor issues)

3D printed the chassis in 2 parts in grey 'PLA tough", glued together, then assembled.
(single part print was a disaster)

and the case fits together, *and works*! (this was a broken hinge psion)

Minor issues: -
1. the base flexes a bit from the hinges, will try another print in PETG to see if that helps.
2. with the "minimal tree supports" print there is quite a bit of clean up, and some of the overhangs are a bit scruffy.
3. the battery compartment seems to be catching slightly and doesn't fully close.

but... this was a non-working psion with a very fragile inner, and now it works and is usable again.

I'm going to experiment with a PETG print next to see if that helps the flex, might test some support changes too, the other option is to see about getting a JLC3D print done in something else 🤔
I'll upload the current model to makerworld, might jot down a blog with all the pics.

#psion #psioncommunity #psion5mx #3dprinting