Creating a Wooden Keyboard for a school project!

[WillPretend]

Hey friends,

For my A2 Product Design project, we were told we could make absolutely anything we wanted, so I took this chance to create a wooden keyboard. So far I've done a lot of research, by scouring certain keyboard forums and other information stores. I've pretty much completed my research so far, but before I start my designing period, I want to ask a few questions to you dudes.

I will definitely be using your input to change my designs, so any help is greatly appreciated. Not only will it be used to change my designs, but I will most likely add any suggestions into my course work, where I get extra marks for any input or changes I get from you guys, and explain a little about it - so seriously, SAY ANYTHING YOU WANT YO.

One thing I need to consider when designing my product are the keycaps, I looked around and the most I could find are these: http://keycapsdirect.com/key-caps.php, I was wondering if I could have your preferences, on what you like best? Or what are the ones that are generally used for Cherry MX boards? Do you have anything else which is important for keycaps? Whilst on the discussion of keycaps, Which is your favorite keycap layout? ISO? ANSI? I was thinking of using ISO, as I'm from the UK, but I've recently been thinking of switching to ANSI, so I can avoid dealing with the funky Enter key.

One of the big things I have considered so far, is how to angle my keyboard, some keyboards use interchangeable legs/stands, some use rubber bullets/stands, and some even have the case built to a custom slant. How important is an angle/slant for you? What is the perfect angle/slant for a keyboard? Do you require your angle/slant to be customizable? (In case you're wondering what the **** I'm talking about - http://ptjournal.apta.org/content/83/9/816/F1.large.jpg (you would not believe how long it took me to find a picture of this)).

Another thing I have been thinking of adding is a wrist rest, normally you would buy them separately, however they often come very expensive, or very ugly. How necessary do you think a wrist rest is? Would you prefer a wrist rest to be removable, or a permanent addition to a keyboard? Would you pay extra for a decent wrist rest?

I'm planning to keep you guys updated with how it goes along, with pictures, more questions and all that crap. I'm most likely going to start some sketches tomorrow, so will update then with the few I will have, and any suggestions you have.

https://docs.google.com/open?id=0BwVTT_irdR4uSDBmTU83aUVCZTQ - Here's my current work if you're interested, albeit a little outdated, I will update this tomorrow when I get to school!
http://www.reddit.com/r/MechanicalKeyboards/comments/zm7m5/need_some_help_for_my_school_project/ - Here's my reddit thread aswell, for a better introduction/layout.

Thanks in advance for your help!

Edit 1: Current most Updated version of my Coursework: https://docs.google.com/open?id=0BwVTT_irdR4uSDBmTU83aUVCZTQ - Will Upload pictures of my initial design ideas on Monday

Edit 2: Updated Coursework as of 17/09/2012 - https://docs.google.com/file/d/0BwVTT_irdR4uMXNfUmlza1pPTVU/edit - First thumbnail sheet - http://i.imgur.com/liA5t.jpg
Second - http://i.imgur.com/OSJQY.jpg

[Pyrolistical]

If you want to do something really crazy, then how about wooden key caps?

I am thinking of a laptop style keyboard where all the keys are flat.  Each key switch is a http://en.wikipedia.org/wiki/Miniature_snap-action_switch

Then you take a single sheet solid wood with a nice grain over the entire surface and cut it up to make key caps but minimizing the gap between keys.  Then realign all the keys with the original grain so your keyboard retains the look of the original hard wood.

Make the entire thing boxy and use a matrix layout (see my keyboard as an example of a matrix layout http://pyrolistical.github.com/blog/2012/08/11/full-custom-keypoard/)

It would look sick and people would not believe its a keyboard.

[__red__]

What is your budget?
What is your timescale?

What tools do you have available?  CNC? Laser Cutter? Molding Equipment?

[WillPretend]

If you want to do something really crazy, then how about wooden key caps?

I am thinking of a laptop style keyboard where all the keys are flat.  Each key switch is a http://en.wikipedia.org/wiki/Miniature_snap-action_switch

Then you take a single sheet solid wood with a nice grain over the entire surface and cut it up to make key caps but minimizing the gap between keys.  Then realign all the keys with the original grain so your keyboard retains the look of the original hard wood.

Make the entire thing boxy and use a matrix layout (see my keyboard as an example of a matrix layout http://pyrolistical.github.com/blog/2012/08/11/full-custom-keypoard/)

It would look sick and people would not believe its a keyboard.

That is pretty wild, although, most of my research has been done around, you know, a normal keyboard haha. That actually does sound awesome, and I like to idea other aligning the keys with the original wood grain.

What is your budget?
What is your timescale?

What tools do you have available?  CNC? Laser Cutter? Molding Equipment?

Hopefully, my budget will be Zero, my school will supply all the wood, and my teacher mentioned that he would get me a couple of old keyboards to play with, although they will be membrane Considering I'm a student I don't really want to spend much, if any, but Recently I've been leaning towards making it with Cherry switches, Any idea how much this would cost overall? I have around 8/9 months to complete it, I do spend around 5/6 hours extra a week on usual with DT, but I'm thinking of putting more in, making it a total of around 20 hours a fortnight, atleast.

I guess I'm quite lucky, our school recently got transferred to a new one which they had built, and it has fancy new ****. CNC, Laser Cutter, Molding Equipment, the lot. And I'm fairly sufficient with Solidworks (3D designer), so there's no holds barred.

Update: I got through 4 potential designs today, hoping to finish the rest tomorrow, and at least by Monday, so will upload them for some feedback soon!

[voightkampffme]

Great project.

Keep us updated.

[WillPretend]

Updated version of my Coursework so far: https://docs.google.com/open?id=0BwVTT_irdR4uSDBmTU83aUVCZTQ

Will upload pictures of my potential designs/thumbnails this monday for a little feedback, need to do one more and then I'll start the more in-depth design ideas!

[suprsmo]

Hi WillPretend,

Had read this thread last week, and thought.. jeez thats a mammoth task..

Then I come into work today and one of the guys from my account, told me he just ordered one of these:

http://www.designboom.com/weblog/cat/16/view/23609/bluetooth-powered-wooden-keyboard-by-oree.html

http://news.cnet.com/8301-17938_105-57513410-1/the-oree-keyboard-is-a-wireless-wooden-wonder/

Interesting. Looks like Scissors are the best way.

Hope this kinda helps.

[WillPretend]

Hi WillPretend,

Had read this thread last week, and thought.. jeez thats a mammoth task..

Then I come into work today and one of the guys from my account, told me he just ordered one of these:

http://www.designboom.com/weblog/cat/16/view/23609/bluetooth-powered-wooden-keyboard-by-oree.html

http://news.cnet.com/8301-17938_105-57513410-1/the-oree-keyboard-is-a-wireless-wooden-wonder/

Interesting. Looks like Scissors are the best way.

Hope this kinda helps.

I've been seeing this a lot recently, It looks really nice - kinda like one of the Apple manufactured keyboards. It's pretty minimal and small, I'm more looking to go for a more bulky keyboard. And also, I'm not too sure how hard it would be to implement Scissors, I'm actually having some trouble about thinking how to implement a switch with a completely wooden case, considering wood isn't exactly going to work like current plastic switches do (where the key kind of gets squeezed through the case - wood won't allow this as well as plastic).  I guess I need to think of something funky.

Anyway! I've done a lot of work recently, and I bring an update!
Okay, so over the past week or two, I've been pretty busy completing my research, which I have finally done, however I m ay add a bit more to it here and there.
Updated Coursework - https://docs.google.com/file/d/0BwVTT_irdR4uMXNfUmlza1pPTVU/edit

Added:

    Keyboard Switch Research

    Client Profile Research (I tried to keep it confidential as possible, just ask if you want anything removed)

    Research Analysis

    Specification

    Thumbnail Designs

    Ergonomical Research Extended

Thumbnail Sheet 1 - https://docs.google.com/file/d/0BwVTT_irdR4uek9GMGhuU05iV0E/edit
Thumbnail Sheet 2 - https://docs.google.com/file/d/0BwVTT_irdR4uUERkczU1VXhiRW8/edit

I need feedback and input on these designs, considering none of my friends, or really anyone in my school are anywhere near as proficient in their keyboard knowledge as you dudes, I would really appreciate it if you can say why you like each one, and why you dislike others. Be as extensive as you like, I really want this to be a good project and have a good finish, so I really want to hear ANYTHING you have to say (not to mention it's required for a good mark).
In the coursework power point, the sketches are numbered, which you can use as a listing with your feedback - thanks in advance for that! (Pages 17 & 18). By the way, I know a few of the designs are depressingly stupid, however, I needed to show some imagination and creative ideas, not to mention I needed 6 different types of keyboards - which was actually pretty hard.

Personally, I really like 1, 2 & 6. 1 would be difficult to pull off, and I reckon it may be trying too hard with the whole movement of the keyboard and that crap. However, if I do manage to pull it off, it could look really nice.
2 is kind of the average keyboard - it would be simple to make, and have an extremely sleek finish. But I feel as if I need to do something a little bit more special. This was my original view of what I was going to make going into the project, however, after a bit of research and inspiration, I feel as if I need to do some more.
I'm really starting to have a preference for 6, I could steam bend some thin wood - most likely a light coloured wood. And then cut this out, where the keys would go through and then CNC the base where all the electrics are stored. This would be pretty difficult and has the potential of looking extremely nice. However, equally it could just look terrible.

Once again, I'd really appreciate your opinions on any, or even all of them!

I'm pretty sure that is it, if I have forgotten anything, I'll just edit this post.

Thanks for reading friends.

In case you care, here is the reddit thread (sorry to just copy and paste) - http://www.reddit.com/r/MechanicalKeyboards/comments/100w5v/update_need_some_help_for_my_school_project/

[Pyrolistical]

Can't see any of those google docs.  The last two are edit links, the first one is a ppt (don't you dare!)

[WillPretend]

Can't see any of those google docs.  The last two are edit links, the first one is a ppt (don't you dare!)

You should be able to view them, I quickly uploaded the Thumbnail designs to imgur for you though friend. And our for some reason the course requires them to be done in a ppt document, It's not like a normal ppt though, there's probably a couple thousand words in there, with around 18 pages of pure keyboard knowledge bombs! (google drive is the only site I know which allows people to view powerpoints without downloading the program and the file itself - It has been slow recently, it may be due to the size of the file, where it has to load a little bit).

First thumbnail sheet - http://i.imgur.com/liA5t.jpg
Second - http://i.imgur.com/OSJQY.jpg

[WillPretend]

I come with another update with some models!

Here are the Model photos: http://imgur.com/a/KFTdO
And of course, the updated coursework (for anyone that wants to take a little gander: https://docs.google.com/open?id=0BwVTT_irdR4uTHlaNnFtaGtQWGs

I would once again like some feedback and input on my designs. If you could tell me your favourite Model and why you like it, but also what you think I could improve on it, I would be extremely thankful. Also, I would once again appreciate it if you would give me some feedback on all the models (tell me why the bad ones are bad, and why the good ones are good). Thanks in advance for your feedback.

I still really like Model 3, I don't think I've really seen a keyboard design like it on sale anywhere, which is where Model 1 kind of falls down - it's too average. Model 2 kind of came out bad with the making process (but I couldn't be bothered to redo it, as it's not too important for the model to be anything special). For a final design, Model 2 would come out and look alike a retro typewriter, if I could pull it off that is.

Once again, ANY input is not only accepted happily - but needed desperately for my coursework!!!

Thanks!

[Pyrolistical]

They are all way too tall.  Remember the best ergonomics is actually negative slope.

http://ergo.human.cornell.edu/ahtutorials/typingposture.html

[mattrm]

Model 3 would be my personal choice, I like the nice smooth curves.  Model 1 is too angular and I don't like the ends on model 2.

I was randomly thinking have you thought of putting some dovetails on the end?  I don't know how thick the wood is, so it might not be practical, but I'm a big fan of them.

[WillPretend]

They are all way too tall.  Remember the best ergonomics is actually negative slope.

http://ergo.human.cornell.edu/ahtutorials/typingposture.html

With Model 2, the angle changes and can actually go negative, I was talking to a teacher the other day about it, and incorporating that into any model would actually be kind of straight forward. I think I need to do a lot more thinking about that - the only problem is that I want it to look as best as possible, and with moving parts it's always a bit quirky. I will definitely be fiddling with the height and the angles when I get to the actual real size model/prototype.

Model 3 would be my personal choice, I like the nice smooth curves.  Model 1 is too angular and I don't like the ends on model 2.

I was randomly thinking have you thought of putting some dovetails on the end?  I don't know how thick the wood is, so it might not be practical, but I'm a big fan of them.

Quite funny that, in one of our previous projects a looong time ago we actually made a box with dovetails on it. It could well work with them, but with dovetails it's more about putting different parts of wood together, I think I will probably just cut one big bit of wood with the CNC for the base, you know?

Thanks for both your input, I really will be putting everything you say to use!

[fohat.digs]

I personally like #2, and it reminds me of this steampunk beauty. If you made it so that the S-curves were interchangeable and/or reversible, then there could be a lot of angle options.

[mattrm]

Quite funny that, in one of our previous projects a looong time ago we actually made a box with dovetails on it. It could well work with them, but with dovetails it's more about putting different parts of wood together, I think I will probably just cut one big bit of wood with the CNC for the base, you know?

Ahh, ok.  i had assumed you'd be making a box, hence the dovetails comment.  Hadn't thought you'd CNC it.  I'm a hand tools kinda guy, don't really use machines much, mainly cause they're expensive and partly cause I like my fingers attached to my hand.

[Computer-Lab in Basement]

Are you trying to make something like this?

http://www.ebay.com/itm/Custom-Made-Cherry-Wood-Keyboard-Cherry-Mechanical-MX-/130328228244?pt=PCA_Mice_Trackballs&hash=item1e582af194

[fohat.digs]

I would imagine that since this is a design project, it should have design elements that show off the materials and their characteristics.

Those "retail" wooden keyboards seem to be "woodworking projects" for re-creating ordinary keyboards in a different material, and I don't see any real "design" there, only execution.

A truly successful wooden keyboard project should have some wood-related characteristic that would not be available in any other material.

If that does not make sense in the minutiae of the keys and the case, then maybe a matching set of stands/props/sidewalls/wrist rests in wood might be enough to tie it all together.

[WillPretend]

I personally like #2, and it reminds me of this steampunk beauty. If you made it so that the S-curves were interchangeable and/or reversible, then there could be a lot of angle options.

I actually got a the inspiration for Model 2 from those pictures, I've always wanted to make something with that kind of style, I just don't think wood can really harness the Steampunk style? I'm not sure - I really wish it could, because they truly are great to look at - any input on wood/steampunk would be appreciated.

Are you trying to make something like this?

http://www.ebay.com/itm/Custom-Made-Cherry-Wood-Keyboard-Cherry-Mechanical-MX-/130328228244?pt=PCA_Mice_Trackballs&hash=item1e582af194

Wow, hadn't seen this before. And yes, pretty much, but I'd like my design to have something others don't, something special, as this keyboard is literally just a normal keyboard made out of wood, kind of like fohat.digs was talking about.

I would imagine that since this is a design project, it should have design elements that show off the materials and their characteristics.

Those "retail" wooden keyboards seem to be "woodworking projects" for re-creating ordinary keyboards in a different material, and I don't see any real "design" there, only execution.

A truly successful wooden keyboard project should have some wood-related characteristic that would not be available in any other material.

If that does not make sense in the minutiae of the keys and the case, then maybe a matching set of stands/props/sidewalls/wrist rests in wood might be enough to tie it all together.

What I really dislike with a few of the current wooden keyboards I've seen is the fact they just make the outer case out of wood, and still have plastic bits in the keys and other stuff. When I do this for the final design, the only thing that I want to be plastic/metal are the switches and the circuits alone - anything else just totally kills the feel. I know what you mean, it's kind of hard to attain, the best I can think to do is just get a beautiful grain, I do think most of the positives are wood are from it's amazing aesthetics and really great heavy touch, and depending on how easily/quickly the build goes, I am hoping to add wrist rests and all that jazz.

When getting some feedback from my peers and teachers today, unexpectedly, a lot of them mentioned how they really liked Model 2 and seemed to appreciate the ability to change the keyboard angle in it. However, I really like the design of Model 3, and I'm starting to think of adding this mechanism to it for my final design? How necessary is the angle changer? Does the fact that it may deteriorate the build quality/longevity matter for the improved ergonomics?

I'm all up for adding something like this, it would be difficult, but I really want your guys opinions on whether or not the ability to have any angle you want is worth it.

Thanks in advance for you replies, and ofcourse thanks for your current input!

[Ascaii]

Just some input from me:

I like the look of your model 3, since it reminds me a lot of one of my keyboards...I bought this shell off ebay a long time ago and modded it to fit a g80-3000 inside of it. If it helps you I can provide more pictures of my board.

[SmallFry]

Glad to see that you're getting help now! Is it a PLTW class that you're in?

[WillPretend]

Just some input from me:

I like the look of your model 3, since it reminds me a lot of one of my keyboards...I bought this shell off ebay a long time ago and modded it to fit a g80-3000 inside of it. If it helps you I can provide more pictures of my board.

Any extra pictures wouldn't hurt! Would appreciate them yo

Glad to see that you're getting help now! Is it a PLTW class that you're in?

I'm in England, so I have no idea what that means. The one I'm in is "Design Technology: Product Design".

[SmallFry]

Whoops, I forgot that people can be outside the USA. PLTW or Project Lead The Way is a high school program in the States that is like an advanced placement engineering course.

[WillPretend]

http://imgur.com/a/qvnk4#0

Finished!

Would like to thank you all for your help in the early stages, and sorry I did not keep you all updated throughout the whole build, got a bit lazy

[YoungMichael88]

Wow that's quite the project! Nice work!