I got the middle piece printed last night, and after trimming the screen tabs with a Dremel, fitted it back into the top piece and attached the middle piece. Altogether there are six screws holding both parts together. It's now looking more like a finished console (even though there are still more things left to work on).
The screen fit is very good with no adhesives. It doesn't feel loose, even when shaking around the whole thing.
A front side view shows the speaker holes for the mono speaker in the middle. I think this will need re-designing too, because the walls between the holes are very thin.
Remember that the bottom piece is still missing, so this handheld will be ~5mm thicker than it looks here when it's done. But these two parts already provide a good mockup for how it will feel holding it in your hands.
The area for the shoulder buttons did feel weak, but it's less of a problem after attaching the main top shell piece. One area that is still flimsy is the top center of the screen. There is some flex in here because there are no supporting tabs like there are in the other corners or opposite side. A reprint of the top shell would have the additional tabs for a more secure, sturdy feel.
There's also a side port for the TF card on the left. but ports are still missing for the power button and battery charging, and auxiliary buttons for different input modes, so this is not the final version. For now the focus will be on lining the Lark Box motherboards and designing the parts to support the buttons from the inside.
I'll be getting a different color for PETG filament and try different colors to print out.
