My last keyboard build was a
matrix style split hand. It turned out really nice but after using it for awhile, I've decided that I don't really like the matrix layout. So my next project is to design a Microsoft Natural style split hand board. I haven't finalized the exact layout yet, but there are several possibilities which will probably all work fine. A full size version and a more compact version which I both like are shown below. A big advantage of these designs over my matrix split hand is that standard keycaps can be used for everything except the space bar. I've shown 2u space bars below because I'm planning on using caps from the GMK Carbon drop w/ the 2u keys from the ErgoDox companion drop. Using 2.25u and/or 2.75u space bars would allow shift keys from other sets to be used as spaces but I don't particularly like that idea since I don't think it will ever look as nice as at should (especially given how much it will cost to build).
The biggest problem I'm having is whether the hands should be tented or not and the case design. If everything is done in a single plane, it's easy. A single PCB can be created and a standard laser cut plastic layer case will work just fine. However, I really like the light (~8 deg) tenting that's in the MS Natural keyboard and would love to duplicate that. That adds a lot of complexity though: 1 PCB turns into 3 separate PCB's that will have to be connected together, and the case becomes much more complicated. Maybe even too complicated for me to attempt.
So here's a few questions I'd like help with. Any ideas you have would be great to hear.
1) How would the 3 separate PCB's be connected together? Assumes they're connected inside a single case so nice, external connectors aren't required.
2) How can a case be designed to hold a series of tilted planes (see attachment below) that would be as easy and cheap to build as possible while still looking nice? For starters, assume that the 3 planes (left hand, right hand, num pad) are only tilted in one plane. I'm assuming any front to back tilting can be handled some blocks under the back of the case. Obviously 3D printing would work, but that's a big thing to 3D print, I'm not sure how nice it will look, and doing the design work is beyond my current experience.
One advantage of my split hand board was that the switch plate was plastic (i.e. cheap) but that only worked because it was supported by the bottom of the case. I could duplicate that kind of sandwich design and make 3 separate keyboards, connect them with external cables, and then build a stand or base of some kind to hold them together in the arrangement I want. That might be my best option at this point, I'm just not sure it will look as nice as a good custom case.