Hi everybody! After a few successful runs of my Galaxy Class keycap set (thanks, as always, to moz for getting the ball rolling on that), I've been thinking for a long time about a fun new project to do. I'm a huge Topre fan, but I also love my custom MX keycaps, so it was a pretty natural step for me to want to do something for the Novatouch. My current daily driver is a heavily hacked hybrid 45g/30g-weight Realforce in a custom Korean CNC aluminum case from a run that KBDMOD did. I
love that case, and it's the only thing keeping me from switching over to Novatouch full time. So, it's probably no big surprise what I've been working on. Here is my latest custom CNC-milled, black anodized Novatouch case prototype.
I've admittedly gone a little crazy (in a fun way) with this project. Firstly, I had to teach myself machining and metal finishing (I machined the first prototype myself on a manual Bridgeport mill), and then 3D CAD, and then how to work with prototyping shops, and then how to work with manufacturers to organize production runs. To my slight embarrassment and horror (now that I am writing this and look back on it), I've now gone through thousands of dollars making four iterative one-off prototypes and about a year of work, but I'm really very happy with the design at which I've arrived. The better (later) prototypes have been purchased by GeekHack members through the Classifieds, and I have been so encouraged by their very positive feedback on receiving the cases and have heard from so many people who are also interested that I have decided to try to maybe organize a larger group buy.
I thought I would document the design process here, explain the decisions I made and why, and then I wanted to solicit feedback from the community and see what kind of interest there might be.
Massdrop are very interested in organizing an initial buy, so at this point I think I'm likely to offer these through MassDrop, but I'm open to feedback on that as well.
DesignI have designed a well to hold the plate, with alignment pins to help when screwing the top and bottom together with socket-cap screws.
An additional feature added in subsequent versions (not shown above) are flange-head screws that cinch the plate against the bottom half of the case, allowing firm and precise tweaking of where the plate sits in the case and then a positive lock between the parts. This is especially in case there are significant tolerance variations between keyboards now or in future from CoolerMaster, causing the plates to be slightly different sizes. You can see the hole and recess for the flange screws in this photo of a later prototype.
Exterior corners have a nice chamfer to break the hard edge.
(It may look like the top and bottom don't precisely align here, but that's just because I took this photo without the case fully assembled.)
The USB bracket screws into tapped holes and on the outside of the case sits flush with the face of a recess that has been made to the precise connector specs given in the USB standard.
Two feet options are provided. Firstly, my preferred (and the more generally recognized to be ergonomic) totally flat, using very low-profile bumpons to keep the overall case profile as slim as possible.
Secondly, if I do a larger run of these, I'll include the option for riser feet, which will allow raising the case to the same angle as a Novatouch with its flip-up feet deployed (11 degrees).
I originally included a logo (what used to be my GeekHack avatar), but I have removed that for the production run.
Feedback please 
Would you buy something like this? Any requests for improvements?
I know many folks might like different colors, but anodizing is crazy expensive, and every additional color doubles the anodizing cost for the group buy. I figured black was the safest bet.
Made in the USAI am leaning towards production in the USA, because I believe it'll ensure a shorter lead time and (possibly) higher quality compared to sourcing in China, even if being more expensive. I have nothing against working with China vendors—all of my prototypes were made in Shenzhen—I just think it makes less sense for very small production runs compared to thousands of parts. It also means lower risk for everyone involved, much less complicated logistics and shipping costs, etc. I'm also a stickler for quality and want to make a high-end "luxury" sort of keyboard mod product if I do this, and I believe that working with a local vendor will help me with quality control.
My goal would to have these ready to ship within two months of money being received from buyers in any group buy. Assuming I go with a US shop, I think that is a realistic timeline. If we go with a vendor in Asia, we have to worry about sea freight, customs clearance, and all that, which always introduces greater risk for delays.
Cost and timeBecause I'm sure someone will ask, I don't yet know the final price. But custom, short-run CNC machining and finishing aren't cheap, so let's pessimistically assume $250 if only a few people join the buy, but I think even with USA manufacture that we can probably do better than that (or
much better if the numbers are strong). Of course, it's all depending on what options I end up going with and what numbers we're able to generate—hence this IC thread!
I look forward to hearing your thoughts, my fellow Topre nerds!
Poll