Smasher816, nice write up! Thanks.
Xe0n0, elecrow.com(or other fusion PCB serivces like seeedstudio will also work) don't need BOM file to manufacture PCB, just send gerber files; plot/HHKB_controller_fusion_B140314.zip.
And order components at digikey(or mouser?) according to BOM.txt.
Use Japanese products to help our sinking economy if possible like Panasonic or KOA for resistors, Murata or Taiyo Yuden for capacitor, Alps for switch and Hirose/JST for connector. They are reliable enough, I think.
EDIT: Bluetooth option of Rev.B is not confirmed at all yet, I have no time to do that.(And Rev.A has apparently a problem on power control.) If you want wireless connection you have to wait, but both Rev.A and Rev.B are confirmed for USB.
Thanks for your information!
Just checked for fusion PCB service. It seems it will only produce the PCB board, and I have to soldering components by myself.
I try to figure out the all the material I have to buy and how to install them, so I combined the BOM.txt with material list generated by KiCAD. I post it here, just need some help to clarify some details.
USB-mini connector 1 Hirose UX60SC-MB-5ST J1
Chip 1 ATMega32U4-AU TQFP 1
Xtal 1 HC49 16MHz SMT X1
Capacity 2 22p 1608 C5 C6
Capacity 6 0.1u 1608 C3 C7 C8 C9 C10 C13
Capacity 3 1u 1608 +-10% C4 C11 C18
Capacity 3 10u 3216 C1 C2 C14
Capacity 1 22u 3225 or 3528 or 3216 C12
Capacity 1 47u 3225 or 3528 or 3216 C15
Resistor 2 ?R ? R17 R18
Resistor 2 15k ? R9 R24
Resistor 10 10K 1608 R1 R6 R7 R8 R11 R12 R15 R16 R22 R23
Resistor 5 1K 1608 R4 R5 R10 R21 R25
Resistor 2 ? R470 R13 R14
Resistor 2 22 1608 R2 R3
Resistor 1 0 R19
PPTC500mA 1 TYCO nano PPTC1
FET-PMOS 2 Q4 Q5
FET-NMOS 3 SOT23 Q1 Q2 Q3
15pin connector 1 DF14A-15P-1.25H CN1
13pin connector 1 S13B-ZR-SM4A-TF CN2
LED 9 2012 D1 D3 D4 D5 D6 D7 D8 D9 D10
Diode Schottky 1 SOD123 D2
Bluetooth 1 RN42 U5
Lipo Charger 1 LTC4054 U4
Lipo connector 1 JST PH2 P100
3.3V Regulator 1 TAR5SB33 U2
Inductor? 1 L100u L1
SW-PUSH 1 Alps SKHH or SKHL SW1
SW-SLIDE 1 DPDT SW2
5V Boost converter 1 HT7750A U3
Is resistor valued R and 15k also the type 1608? (Resistor valued R is not included in BOM.txt, so it will be embed in PCB board?)
Value of resistor on R19 is 0...And it's marked with "Resistor is not implemented", so I just ignored the slot?
What's the proper type of the inductor "L100u" on L1?
I try to check your photo on http://geekhack.org/index.php?topic=56494.0
for detail, but this picture is not clear enough...Do you have an updated an closer photo of the Rev.B board? It would be easier soldering with that.
PS: I contact a manufactor and they told me they can help do the SMD things if I provide BOM sheet with detail slot number.