I'm sorry that you had so many troubles in making an alu case, I just wonder what process are other people using since it is used almost exclusively on all the keyboards that I've seen in these years. Probably the main problem you encountered comes with the bending.
other keyboards? you mean the CNC custom keyboards? every IC/GB carefully explains what kind of material, production method and surface treatment or finish is used, no need to wonder. it is mostly aluminum, cnc, bead blasting and anodizing.
and yes, the combination of bending and aluminum was one of the main issues. that's why on most PC cases that come with an aluminum front you see these huge radiuses. there was more to it, for example sheet metal aluminum comes in different alloys compared to aluminum blocks for CNCing -. not the same result after anodizing.
Anyway steel is good, if you use stainless steel, it's even better. What thickness are you going to use? I just wonder how does aluminium sound in comparison. Probably steel is going to sound higher pitched than aluminium.
when powder coating, you certainly don't use stainless steel, that's a waste of money. the coating protects the steel and prevents it from rusting.
It's 1.5mm thickness. with this thickness the 60% already weights 1.35kg (mentioned in the start post).
imo the sound is influenced by the density of the material and overall mass/weight of the case (and more factors of course). what also plays a major factor is the decoupling/dampened mounting of the plate. I think it sound deeper compared to alu, not any resonating sound due tue the density of the material and even more due to the decoupled mounting of the plate. to me it's immediately, deeply satisfying
like mentioned in the start post, I'll send to next prototypes to reviewers who can review/test it - they are in a better position to give you a detailed opinion about sound and more.
And remember that even if its inox, it still rusts when it's dirty... So it should be really high quality steel.
yes, thanks, I do know that. the company that does the powder coating uses a five phase cleaning procedure. intensive and automated cleaning is a standard procedure before the coating. again, you just use standard steel when you powder coat, definitely NOT stainless steel. though there is a huge number of different steels to choose from. I have friends who work in engineering and automotive, so I have ways to figure out what the most suited alloy is.
please, if you you have actually worked with metals in the context of engineering, industrial design or automotive design and you actually know what you are talking about, then good. but otherwise you just cause confusion. no offense, I know you mean it well.