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Yep -- just held by the pieces around it seems to be okay. No slight to your STL implied -- I didn't pull your STL; quicker for me to start from scratch. Re. the fillet, it would contact the grommet, which is somewhat curved; I suspect the compromise is worth it. Here's my current revision...

I was surprised to find that apparently reefcheck.org does indeed offer OW, AOW, and Rescue, continuing to AAUS -- or perhaps they move people through a more widely known program but under their aegis: https://www.reefcheck.org/dive-into-science-program/

Okay, fixed the dimensions to match an original. This roll of TPU is a little old and damp, so some ugly stringing -- but doesn't materially affect the outcome. I put a little chamfer on the leading edge of the smaller disc; I'm thinking there should be a substantial fillet where the...

Backplate (only) sold; remaining items, and hardware/harness from backplate still available.

@TT_Vert @Johnoly what do you think of this for printability? Print, fold, insert. (Dimensions not correct yet; I just sketched it by eyeball to get the concept down.)

Or slice them down the stem axis into two identical halves (which then print on the flat sliced surface, giving the good layer direction), and then perhaps glue them together — or perhaps not; they might self-stabilize once both halves were in.

These might not work in practice; Tobin’s are 1/2” dia at the retention flange and 1/2” thick — but they’re fairly close: https://www.mcmaster.com/products/bumper-cushions/extra-grip-push-in-bumpers~~/for-material-thickness~17-32/for-material-thickness~9-32/

@TT_Vert If you just need a couple, I’ve got two that I thought I’d need and never did. DM me your address. (With the “big window” DSS wings I kinda see the utility, but still helpful but not necessary.) (Unless anyone wants to start a bidding war…) They’re definitely injection molded...

FWIW, I have the Accel but replaced the straps with spring straps.

I always got a laugh out of @Trace Malinowski ’s description of ISE: (From Agency Culture (Truth in Humor?))

You buried the lede: your target cost is about $35.

Oh, yes: Ignore the lean, or just grab the backplate and give it a quick wrench to straighten it out. Doesn't really affect the diving. (Or buy the inexpensive and high quality STA I have in the same post. But you don't really need it.)

The last ones you pictured work the same way you describe the Halcyon working -- the two ends separate. (Not familiar with the exact ones you pictured, but the general concept I've usually heard called "Scubapro style" or Scubapro SuperCinch.) I prefer that, but it sounds like you want the...

With an aluminum BP and Al 80, and wearing a new-ish 3 mm full suit and well-worn tech shorts, I need just 8 lbs. of lead, which I split between trim pockets on the cambands and a belt. I believe this setup is "balanced"; I'm able to hold a safety stop with a nearly empty tank and to swim up to...

Really? Oh, I have to rethink that piece then; I assumed the thumbscrew went in the plastic bump side of the nut first, and the bump was to self-center on a matching feature in the sheath, facing toward the thumbscrew. No?

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Let's confirm the threading (I still suspect it's #6-32, but could be M4x0.7) and need the screw length: Also, when you assemble it, do the screw threads engage with the plastic on the nut side at all, or is the plastic clear of the threads and they only engage with the actual nut?

Got it; missed your second post. Fastener could be an M4 but some of the other dimensions seem to be inch-derived, and you measured at the shoulder, so I'd bet it's an ANSI #6. Did some rounding estimation assuming the engineers were inch-people. ...and did a quick-and-dirty knob side just...

What’s the thickness when including the raised island? What’s the threading?

(It really bugs me when ideas won't leave me alone. Maybe sketching this will satisfy the voices, at least until somebody sends actual dimensions.)