Aluminium TKL Case - TEK-80 - CAD Files inside!

[cyberwave]

no prob! 

can't wait for this case

[cobraj]

Ooooooft.
Looks impressive.

[WhiteFireDragon]

Looks nice Photekq. Just keep in mind that every detail you add will increase price. So that extra ledge for stock Filco plate is considered a detail. Also while you design it, keep in mind the tooling required to actually mill it out. For example, I don't think it's possible to have perfect sharp right angles on the inside corners because the milling bits are rounded. You'll need rounded corners, aka fillets in the design. Try to keep fillets the same sizes too so during manufacturing, it won't require a tool change, which will probably decrease costs.

current universal plates already have trouble fitting costar stabilisers properly due to its thickness

if your plate is even thicker than that, i doubt costar stabilisers can be used

I see.. No wonder WFD sanded the stabiliser holes down for me. Right, well, the plate won't be 2mm anymore. It'll probably be closer to 1.5. I'll look more into this - thanks for letting me know.

Yeah for the later wave of plates I sent out, I filed down the costar slot if you filled out the form for any keyboard that uses costar stabilizers. 1.5mm should be perfect. It's too bad that US uses the gauge system for standard thickness, so there were no sheet metal places that had 0.060", only 0.0625".

[Photekq]

Looks nice Photekq. Just keep in mind that every detail you add will increase price. So that extra ledge for stock Filco plate is considered a detail. Also while you design it, keep in mind the tooling required to actually mill it out. For example, I don't think it's possible to have perfect sharp right angles on the inside corners because the milling bits are rounded. You'll need rounded corners, aka fillets in the design. Try to keep fillets the same sizes too so during manufacturing, it won't require a tool change, which will probably decrease costs.

current universal plates already have trouble fitting costar stabilisers properly due to its thickness

if your plate is even thicker than that, i doubt costar stabilisers can be used

I see.. No wonder WFD sanded the stabiliser holes down for me. Right, well, the plate won't be 2mm anymore. It'll probably be closer to 1.5. I'll look more into this - thanks for letting me know.

Yeah for the later wave of plates I sent out, I filed down the costar slot if you filled out the form for any keyboard that uses costar stabilizers. 1.5mm should be perfect. It's too bad that US uses the gauge system for standard thickness, so there were no sheet metal places that had 0.060", only 0.0625".

I'm going to keep all the features in and see what it will cost. If it's too high then I will have to remove some stuff, but I would like to keep as many features in as possible. Also, do you really think those platforms would increase the cost? I would've thought they would have decreased the cost since it's less aluminium that needs to be removed.

And yeah, I found out about the fact that all internal corners need to have a radius a week or two ago. It'll all depend on where I get it made - if they have bits with a low enough radius it'll be fine, but if they don't then I'll have to add circles at the edges like the Vortex case.

[CPTBadAss]

Think about it this way Photekq. If you have a platform, that means there's going to be a dimension associated. That means someone has to mill/machine it out. And then someone else has to measure it. So now you have to pay 2 extra people at least just to get it. WFD is right, every single detail you have will add to the cost.

[Photekq]

Think about it this way Photekq. If you have a platform, that means there's going to be a dimension associated. That means someone has to mill/machine it out. And then someone else has to measure it. So now you have to pay 2 extra people at least just to get it. WFD is right, every single detail you have will add to the cost.

You're right.. I didn't think of it like that. I was thinking that entering a few more pieces of code into the routing would take less time than the time it would take for a milling machine to cut out those extra pieces of aluminium.

[Photekq]

I know this thread's been dead for a while now but I thought I'd make some updates for those who are interested.

1. Core design is 100% done.
2. I have found a place to get the prototype made.
3. I've been quoted between £300 and £450 for the prototype (not including the plate). This is just about affordable for me at the moment.
4. I can't get the prototype made until early July due to my GCSE exams.
5. Platforms for stock Filco plate may not be in the final design. Please post here if you would genuinely use the stock plate over a custom plate that mounts better and allows you to remove the top half of switches without desoldering. I don't have quotes on the plates yet but I doubt they would be too pricey.
6. There is a possibility of the object in the picture below making an appearance in the prototype. If I ever make more then it won't be there in order to cut down the price. All depends on how much it will add to the costs - I would personally love to have it in the design so if it's within my budget I will put it in. Any guesses what it is?

[Acanthophis]

Any guesses what it is?

A heavier metal alloy than aluminium for additional weight inside the bottom tray of the case?

[jdcarpe]

yeah, brass

[Photekq]

Any guesses what it is?

A heavier metal alloy than aluminium for additional weight inside the bottom tray of the case?

I made it too easy, didn't I?

Oh, and I forgot to put in the update post that there's only a possibility of it being in the prototype. If more ever get made the brass/stainless steel plate won't be implemented.

[CPTBadAss]

Brass weight like the 356CL!

I think the custom plates with the solderless switch design is a better idea vs the Filco plate. And I'm loving that design mang. Nice work mate

[Photekq]

Brass weight like the 356CL!

I think the custom plates with the solderless switch design is a better idea vs the Filco plate. And I'm loving that design mang. Nice work mate

Thanks man! It actually was the 356CL that inspired me to put it in. I was looking at it for about the 1000th time the other day and thought : Man I've gotta put an awesome brass plate like that in the prototype.

[CPTBadAss]

Ahaha, I do the same thing. Prolly check out the 356 boards once a week.

[korrelate]

I didn't say it was better than USB, just that it was better than mini USB. Although I do think it is better than USB because it is a smaller and cleaner connection. But it's better than mini because it's smaller, sturdier, and has a higher disconnect capability than mini.

http://en.wikipedia.org/wiki/Universal_Serial_Bus#Mini_and_Micro_connectors

Regular size USB doesn't work since it's so damned big, not easy to stick in a keyboard where you have minimal bezel size.

mini USB can be painful because you are supposed to engineer the housing to supply the vast majority of physical support.

micro USB provides some improvement to mini, but primarily by making it easier for the housing to provide the physical support.

Thanks. I'll look into it further. From what you've said micro sounds great.

Just a quick idea here: I found a site through GH that sells custom cables (can't remember the name) but one of the things that really stuck out here was a quick-disconnect option that he seems to be selling. The idea is basically: run usb-to-QuickDisconnect from the interior of the case to the exterior and then let the user pick the connection he would like; quick-disconnect to USB, microUSB or miniUSB (or even PS/2)?

If at all possible, I'd have to say this idea has some real legs. The MTBF of a USB connection can't be anywhere near the MTBF of the Quick Disconnect.

[Photekq]

Just a quick idea here: I found a site through GH that sells custom cables (can't remember the name) but one of the things that really stuck out here was a quick-disconnect option that he seems to be selling. The idea is basically: run usb-to-QuickDisconnect from the interior of the case to the exterior and then let the user pick the connection he would like; quick-disconnect to USB, microUSB or miniUSB (or even PS/2)?

If at all possible, I'd have to say this idea has some real legs. The MTBF of a USB connection can't be anywhere near the MTBF of the Quick Disconnect.

Thanks for the feedback but the USB mounting is completely set in stone. A breakoutboard screwed directly into the case will be solid and I'm very happy with the current USB design.

Also, having a micro usb port is a much more elegant solution. It may give people less options but I'm confident that everyone will be happy with micro usb.

[ishtob]

I've also read that micro usb is able to take a lot more stress than mini usb ports

[Photekq]

I've also read that micro usb is able to take a lot more stress than mini usb ports

That's a bonus but I mainly chose it due to the fact that the cable won't come out unless you want it to. The same can't really be said for mini usb.

[WhiteFireDragon]

Any guesses what it is?

I made it too easy, didn't I?

This was the riddle of the century. What screws down to the bottom, adds weight, and brass colored?

It can't be a brass plate. It must be keycaps 

[Photekq]

Any guesses what it is?

I made it too easy, didn't I?

This was the riddle of the century. What screws down to the bottom, adds weight, and brass colored?

It can't be a brass plate. It must be keycaps 

Hahaha.. I shouldn't have made it brass coloured. It's blatantly obvious that it is in fact the elusive case-sized brass keycap.

[Moosecraft]

How's it going with this case?
Sorry if it's been answered before in the thread.

[Photekq]

How's it going with this case?
Sorry if it's been answered before in the thread.

Design is done and I have found a place to machine it. Prototype will be costing me between £150-300 for the machining and around £100 for materials. I'm literally just waiting until my GCSE exams are over and then I'll concentrate on getting the prototype made.

I haven't actually posted any pictures of the case itself in a while, so here are a few. It should give a good idea of how it's going to look.

[rindorbrot]

I want it now!!!

[Photekq]

I want it now!!!

I do too, man. This case is the first component of my dream keyboard. Unfortunately we've just got to be patient

[rindorbrot]

I know that I have to wait

Have you decided, which color options will be available?
And what about plate layouts, can we get some one of a kind ones?

[Photekq]

I know that I have to wait

Have you decided, which color options will be available?
And what about plate layouts, can we get some one of a kind ones?

Anything is possible just remember that lower quantities costs more. I'm happy to design any plate layouts and have them made as long as you pay what it costs me. Anodising options will come at a later date since I haven't yet found a place to get anodising done and colours vary from company to company.

[dirge]

The front elevation is quite high, My vortex is only 2.2mm'ish

[Photekq]

The front elevation is quite high, My vortex is only 2.2mm'ish

You're right. The case is extremely high profile, 32mm at the front as shown in one of the pictures. This is due to the brass plate and because I love the look of high profile cases. I think a wrist rest is something you'd want to use with this case.

[rindorbrot]

How about a matching wrist rest then?

[Moosecraft]

Wow if it's to high to use without a wristrest I won't be able to use it becuase if I would use a wristrest I would get so much carpal tunnel problems again...

[Photekq]

How about a matching wrist rest then?

Next thing I'm going to do, along with a numpad case if I can get the money.

[esoomenona]

I'm not sure if this was mentioned, but technically, for the 7bit layout, you'd need all of those bars between escape and the function row gone.

[Photekq]

I'm not sure if this was mentioned, but technically, for the 7bit layout, you'd need all of those bars between escape and the function row gone.

Yeah, I didn't realise that when I started this but I know now. I haven't made 7bit or winkey tops for the current design yet.

[esoomenona]

The truth is, I almost like it like that. For me, personally, I would leave the one between escape and the function keys, and cut out all the rest.

[Photekq]

The truth is, I almost like it like that. For me, personally, I would leave the one between escape and the function keys, and cut out all the rest.

Like this?

[esoomenona]

Mmmm, yes!

[jdcarpe]

Actually, like this...

[Photekq]

Actually, like this...

Show Image

I meant moose's ideal layout. I'm aware 7bit has no gap between the esc and function row.

[jdcarpe]

Actually, like this...

Show Image

I meant moose's ideal layout. I'm aware 7bit has no gap between the esc and function row.

Ah, okay. Well, the "7bit" one works for my HHK150 design, as well, so that's the one I would want. I think moose ordered a HHK150 plate also.

[esoomenona]

I did, but there are things I don't like about it. For instance, the split backspace. (That might actually be the only thing...?)

And technically, the one he posted as my ideal would work with your plate as well, by my calculations. The space between Esc and F Row is one key. That would leave the rest open, adding one additional key after the function keys.

[Photekq]

I did, but there are things I don't like about it. For instance, the split backspace. (That might actually be the only thing...?)

And technically, the one he posted as my ideal would work with your plate as well, by my calculations. The space between Esc and F Row is one key. That would leave the rest open, adding one additional key after the function keys.

Correct. The gap is 1x, so by having it you'd just be losing one key. The layout would still work aside from that.

[jdcarpe]

Actually, I would like something like this, with 1.5x blockers on the ends. Moose?

[Photekq]

Actually, I would like something like this, with 1.5x blockers on the ends. Moose?

Show Image

Wow. That's something I've never seen before. I like it!

Like I said to someone earlier I'm happy to make any plate/top adjustments and have them made. Just understand that it'll most likely cost extra if the quantities are lower.

[esoomenona]

With the block between Esc and F row, I think that would be pretty darn nice.

[Photekq]

With esc gap : http://i.imgur.com/xXdxK1o.png

Without esc gap : http://i.imgur.com/YUlg3cR.png

[esoomenona]

.

[Photekq]

With esc gap : http://i.imgur.com/xXdxK1o.png

(Attachment Link)

[dirge]

Actually, I would like something like this, with 1.5x blockers on the ends. Moose?

Show Image

love it!

[SmallFry]

Actually, I would like something like this, with 1.5x blockers on the ends. Moose?

Show Image

U cray cray bro. CRAY CRAY.

[Photekq]

Dirge made me think about how high profile the case is. I think 32mm at the front is a little on the extreme side so I've lowered the case 5mm. It's still high profile but not quite as extreme. This did, however, mean I had to make the brass plate 5mm thick instead of 8mm thick. Not too big of a deal though.

[remedyhalopc]

IMO the lower the profile the better.