Building a Custom Mechanical Keyboard

Introduction

• Building a custom mechanical keyboard offers endless possibilities for personalization.
• Partnered with PCB Way to demonstrate creating a bespoke keyboard prototype.
• The method described aims to simplify the process for those with minimal electronic experience.

Prerequisites

• No need for:
  • PCB designing experience
  • Programming experience for keyboard firmware
  • Expensive 3D modeling software (uses free Fusion 360)
• Requirements:
  • A computer (Windows used in demonstration)
  • Soldering iron and basic soldering skills
  • Fundamental understanding of 3D design or ability to learn via tutorials
  • Optional: Access to a 3D printer or a printing service like PCB Way

Designing the Keyboard Layout

• Start with keyboardlayouteditor.com to experiment with keyboard designs.
• Customize layout properties: add/remove keys, adjust key legends, sizes, colors, and positions.
• Discussed personal design choices, such as moving the number row to a compact numpad on the right.
• Save the layout via permalink for future reference.

Creating CAD Files

• Use builder.swillkb.com to generate CAD files for keyboard plates.
• Import layout data into the site, choose parameters (MX style switches, Cherry stabilizers).
• Export the layout as a .dxf file for use in 3D modeling.

3D Modeling with Fusion 360

• Import the .dxf file into Fusion 360.
• Extrude the plate to required thickness and ensure proper measurements.
• Adjust the plate for switch stability and create cutouts for stabilizers.
• Begin designing the keyboard case around the plate:
  • Create walls and standoffs for screws.
  • Incorporate USB port cutout.
  • Finalize design, ensuring all components fit.

Printing the Keyboard

• Utilize PCB Way's 3D printing services for ease and precision.
• Upload STL files, choose material, and review design with PCB Way's suggestions.
• Received printed parts with high satisfaction.

Assembly

• Snap stabilizers and switches into the plate.
• Wire switches to form a matrix using diodes for rows, wires for columns.
• Ensure wires do not interfere with screw holes.
• Attach the Teensy microcontroller board.

Creating and Flashing Firmware

• Use kbfirmware.com to create custom firmware.
• Map keyboard’s rows and columns accurately.
• Customize key functions through the site.
• Download firmware and flash it onto the Teensy board using Arduino IDE and Teensyduino software.

Final Assembly

• Adapt USB connection to USB-C using breakout boards.
• Assemble the keyboard by connecting Teensy and screwing the plate into the case.
• Add keycaps.

Conclusion

• Provided a sound test of the finished keyboard.
• Encouraged viewers to explore designing their custom keyboards using the resources shared.
• Offered files for download to build the featured keyboard.