OK!
My fault! I have been updating the Rukia thread here:
https://geekhack.org/index.php?topic=100216.300And it all pertains to the Irma project as well. BUT I should have kept updates in this thread also, even if just a hyperlink to the post in the other thread.
I am SO sorry for that. I didn't keep my word. I should have considered that people wouldn't necessarily be interested in both boards just because they're intended to be made of the same material. Different form factors, different interests.
Again, I apologize.
As for updates since the last post, I'll summarize:
Basically, UHMW has been too difficult for every manufacturer I've worked with to CNC. They either lie and say they can do it, then end up with warped prototypes that I have to get a refund for. Or they flat out tell me they won't work with the material. Or they give me unacceptable tolerances. Or they give size constraints due to the warping (no longer than 5").
Injection molding is the answer. But third party injection molding is way too expensive.
Nitrogen infusion is not as complicated as it sounds, though. And an injection molding set up, once done right is pretty easy to operate.
Highest costs are the machining done for the molds. It has to be an exact fit, so material has to be shaved off little by little, checking fit after each pass. That takes time and effort that fabs are going to charge a lot for.
My solution is that I should have my hands directly on the manufacturing...I should be the manufacturer.
So I'm using the Rukia (formerly plastic Alice) project to fund that endeavor. It's a polycarbonate Alice form factor for the first run, then UHMW down the line. Full carbon fiber sandwich is very likely coming sooner than anyone expects.
What I've come up against, though, is that for a first GB, I should keep numbers low to keep quality high. This also makes turnaround much faster, which is better for the buyers, but also lets me get moving on this--Irma--my first project.
Also, I made my profit margins waaay low because who am I? I haven't even done a successful GB yet.
But that leaves me with little to nothing to put into equipment and work space. I'm not intending a giant work shop or production floor like some kickstarters have attempted. I just need three machines and living room size work space to produce these keyboards.
So that's where we're at. Rukia GB is about to drop soon. Rukia will help make Irma happen. This has only really pushed plans back about 90 days, though. I won't let it be a killer setback.
