[IC] CNC Aluminum Case for Topre RealForce TKL keyboards

[need]

While I respect you wanting to leave your mark, and while this would probably not be a deal breaker to me, I would prefer a case without branding.

I actually prefer not to leave my mark. There are exceptions to this were branding can add some beautiful ornamentation to products (the snow caps on Mont Blanc products, for example), but generally speaking I don't like branding for its own sake unless it add something aesthetically to the product. I was mainly responding to requests by others above, but generally speaking I tend to have a strong anti-branding bias and prefer to let the product speak for itself.

As much as I like plain designs, a maker's mark makes total sense to me. Especially for anything that has a sense of craftsmanship to it. When it's overdone though, it gets distasteful quickly.

I think a good rule of thumb would be put it at a place where the user needs to actually try to look for it. There's no point to make it louder than it needs to be. I would prefer a hidden logo to an object that feels anonymous.

Maybe even a date/year would work too. A lot of vintage keyboards have their dates, and it feels really good to be able to have some kind of traceable reference and perspective of when it's made.

[norbauer]

I may be coming around to a similar view myself. Based on my tests so far, it can definitely be machined in this geometry if correct feeds and speeds are used, but I share your concern about brittleness of the end product. That being said, I have notes and examples of a number of consumer products being machined from Corian (including even an electronics housing), so I don't want to give up too early. I'm continuing to experiment.

FWIW, the survey data also suggests that people are at best ambivalent and maybe even prefer the idea of good old aluminum, so I'm exploring that avenue in parallel right now. I feel like aluminum calls for a slightly different design, so I'm working on that right now and then will get a prototype—maybe with hard ano (in black) as an option as some have suggested/requested.

If you can find a company that can machine it properly then you should give a prototype a shot but i think it would be a lot more expensive than aluminum since the finishing process is more delicate. If you did have a successful prototype I might suggest some level of drop tests to test its durability. I think Corian would be a very sweet keyboard case but in a more simple and robust form.

Like a 60% case?

Ya, any case that would only have an outer boundary with some beefy bezels. 40%, 60%, 75%. Corian comes in sheets of 1/4", 1/2" and 3/4" so any depth more than that would require extra man hours to glue together. Glue joints are typically invisible on lighter colors. You would see it on black.

I am able to source solid surface in greater thicknesses that aren't laminated together, but it wouldn't be "Dupont" brand—not that this probably matters at all.

You know, that's a really good point about the 60% case. If my 87U tests don't work out, maybe we'll defer this Corian idea to a smaller more robust design such as a 60%. I really do want to make a case in Corian eventually, though. It has been a longstanding dream of mine, though I realize what a huge dork that makes me.

[B1G_B1RD]

I am able to source solid surface in greater thicknesses that aren't laminated together, but it wouldn't be "Dupont" brand—not that this probably matters at all.

You know, that's a really good point about the 60% case. If my 87U tests don't work out, maybe we'll defer this Corian idea to a smaller more robust design such as a 60%. I really do want to make a case in Corian eventually, though. It has been a longstanding dream of mine, though I realize what a huge dork that makes me.

I haven't seen anything thicker than that. Just check with your local solid surface shop to see what they are able to source from their manufacturers. The glue joint isnt necessarily a deal breaker. The two part epoxy that is used it color matched to the corian color, its just a little visible with darker colors, solid black being the worst.

If you did a design for a 60% case, any kind of angled case might be a challenge for a typical shop that only does countertops. Milling out in flat planes and holes for threaded inserts should be no problem.

[norbauer]

I am able to source solid surface in greater thicknesses that aren't laminated together, but it wouldn't be "Dupont" brand—not that this probably matters at all.

You know, that's a really good point about the 60% case. If my 87U tests don't work out, maybe we'll defer this Corian idea to a smaller more robust design such as a 60%. I really do want to make a case in Corian eventually, though. It has been a longstanding dream of mine, though I realize what a huge dork that makes me.

I haven't seen anything thicker than that. Just check with your local solid surface shop to see what they are able to source from their manufacturers. The glue joint isnt necessarily a deal breaker. The two part epoxy that is used it color matched to the corian color, its just a little visible with darker colors, solid black being the worst.

If you did a design for a 60% case, any kind of angled case might be a challenge for a typical shop that only does countertops. Milling out in flat planes and holes for threaded inserts should be no problem.

Yes, these would be made in Asia by a plastic machining shop with a lot of experience across a wide range of materials. A wider variety of thicknesses of solid surface are available to these vendors beyond what is normally used for countertop work. I have seen sheets available in 30mm thicknesses and above.

[UnFocused]

Oh yes!

I've been wanting a metal case for my RF ever since I built my Phantom with TEX aluminum case.

[norbauer]

I discussed the concerns about Corian machinability and durability today, and they suggest that we withhold judgement until we've seen some samples—that is may turn out better than we're supposing if done properly. Ideally, I'd love to do an option in both materials. That's what this exploration/experimentation thread is for. I'll keep everyone posted once I have some solid info and samples with photos.

[nmur]

I discussed the concerns about Corian machinability and durability today, and they suggest that we withhold judgement until we've seen some samples—that is may turn out better than we're supposing if done properly. Ideally, I'd love to do an option in both materials. That's what this exploration/experimentation thread is for. I'll keep everyone posted once I have some solid info and samples with photos.

i'd feel safe and cozy with good ol aluminium, but corian is intriguing

mostly curious about the feel of the surface finish, and it would be cool to have a white/off-white colour

[ns90]

Dammit. Now I need to buy a Realforce.

[richard912]

Dammit. Now I need to buy a Realforce.

Don't forget to think about getting some MX sliders too

[ns90]

Dammit. Now I need to buy a Realforce.

Don't forget to think about getting some MX sliders too

Well, luckily I already have about 20, AND 4 stabilizer housings.

[sodiumjoe]

I think I would actually prefer dark aluminum, but my wife made some contact lens cases out of corian, it's a lovely material: https://www.kickstarter.com/projects/mooncases/moon-contact-lens-case

She had them CNC milled, but their was a labor-intensive (for both of us) polishing process once they came back from the the shop. I'd be happy to relay/answer any questions if you have any.

[norbauer]

I think I would actually prefer dark aluminum, but my wife made some contact lens cases out of corian, it's a lovely material: https://www.kickstarter.com/projects/mooncases/moon-contact-lens-case

She had them CNC milled, but their was a labor-intensive (for both of us) polishing process once they came back from the the shop. I'd be happy to relay/answer any questions if you have any.

Awesome! That's exactly the sort of thing I had in mind.

[sodiumjoe]

I think I would actually prefer dark aluminum, but my wife made some contact lens cases out of corian, it's a lovely material: https://www.kickstarter.com/projects/mooncases/moon-contact-lens-case

She had them CNC milled, but their was a labor-intensive (for both of us) polishing process once they came back from the the shop. I'd be happy to relay/answer any questions if you have any.

Awesome! That's exactly the sort of thing I had in mind.

Btw, I already took the survey, but I'd be most interested in an fc660c case!

[dailyherold]

Very excited to see how this develops!

[axtran]

FWIW, I would be all in on Corian. I think the RF deserves something that defines it more than aluminum.

[avid]

Corian seems very cool indeed! Especially the white version. And the brass insert that someone mentioned earlier is something id happily pay for. I know some korean (tx) have sold them in the $50 range. Well i guess you could only wish for a 3,5 - 4kg (8-9 lbs) keyboard 

I already have a rf 45g, but this makes me hurry up to pick up a 2nd one in the 55g version.

[donhonk]

Against my better judgement, I'd buy the **** out of this.

The exotic material sounds good too.

[FSund]

Any progress regarding the feasibility of a Corian case?

Also, will the case come in a polished finish?
I'm curious what the finish would look like straight from the machine vs. polished.

[Asbrodeus]

I don't even like TKLs but I feel like I would have to buy this 

[pixelpusher]

I don't even like TKLs but I feel like I would have to buy this 

Ha. I don't need another TKL (have 3 I don't use) and I don't like topre (already sold off one) but I'm going to buy this!

[roostrc0gburn]

this case could be my gateway drug into the world of rubber domes 

[Atredl]

... and I don't like topre ...

When did that happen? I thought I remembered you advocating topre is the best tactile switch. (Totally not stalking)

[PerniciousPony]

I've been quietly stalking this thread, and thought I'd share a few pictures that might be useful to some.  I've got an 86u, 87u, and 89u.  I am also interested in a case with blockers, and have pictures of both my 87u and 86u in the 10th AE 89u case.

Here is my 87u with blockers.  It doesn't carry the same aesthetic as a true winkeyless bottom row, but is fully functional. 

Here is my 86u with blockers.

In my experience, all of the cases have been completely interchangeable between boards, with one exception.  The 10th AE JIS board(the one with blockers) did not have the dip switch cutout as that pcb doesn't have a dip switch.  I simply used a dremel to cut out this recess and now I can swap cases between any tkl realforce whenever I want.

To use your board with blockers on the winkeys, you'd need to take the board apart and  remove the domes, springs, sliders, and slider housings from those switches as seen here.

[consolation]

Sorry if this has already been proposed, but regarding the top inset, make it interchangeable; put 4 holes in the case and make the inset with four legs to fit them, secure with screws from the inside. That way, people can buy more than one insert.

[PerniciousPony]

Sorry if this has already been proposed, but regarding the top inset, make it interchangeable; put 4 holes in the case and make the inset with four legs to fit them, secure with screws from the inside. That way, people can buy more than one insert.

That'd work if the case does have the different tops, but I'm pretty sure the general consensus at this point is for no insert(blank top).

[poolside]

I've been quietly stalking this thread, and thought I'd share a few pictures that might be useful to some.  I've got an 86u, 87u, and 89u.  I am also interested in a case with blockers, and have pictures of both my 87u and 86u in the 10th AE 89u case.

Here is my 87u with blockers.  It doesn't carry the same aesthetic as a true winkeyless bottom row, but is fully functional. 

Here is my 86u with blockers.

In my experience, all of the cases have been completely interchangeable between boards, with one exception.  The 10th AE JIS board(the one with blockers) did not have the dip switch cutout as that pcb doesn't have a dip switch.  I simply used a dremel to cut out this recess and now I can swap cases between any tkl realforce whenever I want.

To use your board with blockers on the winkeys, you'd need to take the board apart and  remove the domes, springs, sliders, and slider housings from those switches as seen here.

Nice pictures, the Stormtrooper one looks very clean 
Thanks for pointing out that detail about the DIP switches.

[consolation]

Sorry if this has already been proposed, but regarding the top inset, make it interchangeable; put 4 holes in the case and make the inset with four legs to fit them, secure with screws from the inside. That way, people can buy more than one insert.

Oops, I got too excited and missed the magnetic part when reading the top post - I do have one concern with that, do you really want magnets around computer stuff? If it's going to be strong enough to hold on to the plate, what happens when you leave a floppy disk or USB thumb drive on top? OK, I jest about the floppy... But, I do think that a mechanical attachment is a better idea; perhaps a lip above the keys where you can slide one edge of the plate, and have it overhang the back for some bolt attachment - I suggest 5.5mm | 7/32" hex heads...  The advantage is that you get a slight lip so you can use it as a tray without the plate (or with a tray insert) and you get a back plate that will give the illusion of the top being a more substantial feature / solid object. It's a trick used by designers in vintage cars a fair bit.

[TelFiRE]

Sorry if this has already been proposed, but regarding the top inset, make it interchangeable; put 4 holes in the case and make the inset with four legs to fit them, secure with screws from the inside. That way, people can buy more than one insert.

Oops, I got too excited and missed the magnetic part when reading the top post - I do have one concern with that, do you really want magnets around computer stuff? If it's going to be strong enough to hold on to the plate, what happens when you leave a floppy disk or USB thumb drive on top? OK, I jest about the floppy... But, I do think that a mechanical attachment is a better idea; perhaps a lip above the keys where you can slide one edge of the plate, and have it overhang the back for some bolt attachment - I suggest 5.5mm | 7/32" hex heads...  The advantage is that you get a slight lip so you can use it as a tray without the plate (or with a tray insert) and you get a back plate that will give the illusion of the top being a more substantial feature / solid object. It's a trick used by designers in vintage cars a fair bit.

USB drives use flash storage. Only hard drive storage is vulnerable to magnets, and even then you have to go completely overboard to actually damage it.

[norbauer]

Just wanted to offer a quick update that the PCB design (required due to the fact that we want a detachable cable) is now done, so I was able to finish my CAD model with the PCB standoffs. It is currently being made by my trusty prototyping buddies in Shenzhen in aluminum. Once the design is verified to fit the plate properly (should arrive to me in about a week), we'll try it in Corian. This way if Corian doesn't work, we'll at least have aluminum to fall back on. Progress, slowly but surely.

[nmur]

Just wanted to offer a quick update that the PCB design (required due to the fact that we want a detachable cable) is now done, so I was able to finish my CAD model with the PCB standoffs. It is currently being made by my trusty prototyping buddies in Shenzhen in aluminum. Once the design is verified to fit the plate properly (should arrive to me in about a week), we'll try it in Corian. This way if Corian doesn't work, we'll at least have aluminum to fall back on. Progress, slowly but surely.

awesome

thx for the update

[The_Boom_Boy]

I think that the material definitely sounds super cool. But anything bigger than a 60% isn no fun. I think that it would be sweat to do a 60% case with an integrated wrist rest to really be touching the cool material all of the time. I don't know.

[fine_italian_leather]

Just wanted to offer a quick update that the PCB design (required due to the fact that we want a detachable cable) is now done, so I was able to finish my CAD model with the PCB standoffs. It is currently being made by my trusty prototyping buddies in Shenzhen in aluminum. Once the design is verified to fit the plate properly (should arrive to me in about a week), we'll try it in Corian. This way if Corian doesn't work, we'll at least have aluminum to fall back on. Progress, slowly but surely.

Would love to get more details on the detachable cable. Will it be possible for us to use mini/micro cables or is it just magnetic fullsize or usb c?

[norbauer]

Just wanted to offer a quick update that the PCB design (required due to the fact that we want a detachable cable) is now done, so I was able to finish my CAD model with the PCB standoffs. It is currently being made by my trusty prototyping buddies in Shenzhen in aluminum. Once the design is verified to fit the plate properly (should arrive to me in about a week), we'll try it in Corian. This way if Corian doesn't work, we'll at least have aluminum to fall back on. Progress, slowly but surely.

Would love to get more details on the detachable cable. Will it be possible for us to use mini/micro cables or is it just magnetic fullsize or usb c?

The way it is designed now is that it's a USB C socket, into which a plug fits that gives it the magnetic functionality. The plus sits inside a recess, so it's pretty subtle. But if you want to forgo the magnet, it's easy to do so.

[moh18one]

Hi there,

As a future owner of an Realforce 10th anniversary edition, I'm definitely interested in your case. Nevertheless, I've something that bother me because I haven't any informations about that.

Will the Realforce case be as bulky as the one from the Leopold FC660C or FC980C ( see the picture below)? or probably bulkier?



Do you have in mind the dimensions of your aluminium/corian case?

Thanks!

[consolation]

USB drives use flash storage. Only hard drive storage is vulnerable to magnets, and even then you have to go completely overboard to actually damage it.

My experience with flash drives near MRI machines (as in room next door "near") says otherwise 


Edit: OK, so the dork that I am, I began to worry that all the dead flash drives were due to other reasons and moving the coat hanger to the other side of the room didn't "fix" anything. After way too much reading: magnetic fields won't damage your nand storage, BUT, changes in magnetic fields will induce a current that can corrupt your data. So, going back to the magnetic snaps, probably not a problem - but potentially you could make it one. I still don't like the idea, but guess having to tell my supervisor that "the MRI machine ate my homework," has made me hyper-sensitive...

[norbauer]

USB drives use flash storage. Only hard drive storage is vulnerable to magnets, and even then you have to go completely overboard to actually damage it.

My experience with flash drives near MRI machines (as in room next door "near") says otherwise  :-[

Edit: OK, so the dork that I am, I began to worry that all the dead flash drives were due to other reasons and moving the coat hanger to the other side of the room didn't "fix" anything. After way too much reading: magnetic fields won't damage your nand storage, BUT, changes in magnetic fields will induce a current that can corrupt your data. So, going back to the magnetic snaps, probably not a problem - but potentially you could make it one. I still don't like the idea, but guess having to tell my supervisor that "the MRI machine ate my homework," has made me hyper-sensitive...

Not to be too cheeky, but I'm pretty sure that MRIs generate slightly more powerful magnetic fields than tiny magsafe connections. ;) Remember that Apple has used these for like a decade, including back in the days of magnetic hard drives (which, actually, I think they still sell). Maybe don't press your thumb drives right against the cable termination to see what happens, but otherwise, I don't think it's an issue of major concern.

[norbauer]

Hi there,

As a future owner of an Realforce 10th anniversary edition, I'm definitely interested in your case. Nevertheless, I've something that bother me because I haven't any informations about that.

Will the Realforce case be as bulky as the one from the Leopold FC660C or FC980C ( see the picture below)? or probably bulkier?

Show Image

Do you have in mind the dimensions of your aluminium/corian case?

Thanks! :)

Much bulkier. It's just part of the RealForce aesthetic, especially the huge PCB overhang at the back. I'm limited by the profile of the keyboard itself with respect to how small I can make it, unfortunately. If you want a slimmer profile, I'd recommend finding a Novatouch and pairing that with one of my aluminum cases.

I'll wait until I've got the prototype back to pronounce on the final dimensions, as I might slim down the front-to-back dimension a bit if it seems too deep. Currently the area below the spacebar is about 1mm thicker than I'd ideally like, but again this is due to design constraints of the plate, which has to tabs that stick out at the bottom for some reason. If it seems OK in person, I'll leave it as is. If it feels to me to be too thick in that area, I'll have to get a bit "creative" with a design solution.

[FSund]

Just switched from my Novatouch (w/norbauer case, naturally!) to my Realforce 88u, and man, it's amazing what difference a proper case does!

Can't wait for an alu (or hopefully a Corian) case for the Realforce.

[elcubismo]

Hi there,

As a future owner of an Realforce 10th anniversary edition, I'm definitely interested in your case. Nevertheless, I've something that bother me because I haven't any informations about that.

Will the Realforce case be as bulky as the one from the Leopold FC660C or FC980C ( see the picture below)? or probably bulkier?

Show Image

Do you have in mind the dimensions of your aluminium/corian case?

Thanks! :)

When I think of the Leopold FC660C case, "bulky" has never come to mind.

[m1kehonch0]

Wow. This is slick. If the corian comes to fruition you can certainly count me in.


Sent from my iPhone using Tapatalk

[stillzman]

Any updates?

[consolation]

...If it feels to me to be too thick in that area, I'll have to get a bit "creative" with a design solution.

If Corian is uncertain due to unknown material properties; perhaps a, small, trial run of cases for the topre numpads would be worthwhile?
 Totally not ^{trying to con you into making a case for my numpad........}

[pixelpusher]

...If it feels to me to be too thick in that area, I'll have to get a bit "creative" with a design solution.

If Corian is uncertain due to unknown material properties; perhaps a, small, trial run of cases for the topre numpads would be worthwhile?
 Totally not ^{trying to con you into making a case for my numpad........}

[norbauer]

I now have the anodized aluminum case prototype in hand, and I couldn't possibly be happier. This is also the first time I've made a design for something involving substantial amounts of reverse engineering where I managed to nail all the details on the first try. Everything lines up and fits perfectly.

Frankly: I really, really like how this turned out. Radii everywhere, and no visible seam! Totally worth the fuss.















I'm now sending the verified design to the Corian manufacturer to see if they can pull off this design in that material. If that falls through, however, I'm delighted to observe that aluminum makes for a fantastic option. In that latter scenario, we could have a group buy rolling in just a couple of weeks.

Note that this doesn't have the PCB and magsafe cable. Those are on the way soon hopefully.

Also I've shown it here with the risers installed. Unlike the original RF itself, It can also be used dead flat (my own preferred orientation).

I look forward to hearing what you all think!

[elcubismo]

I don't have a realforce, but that looks incredible! Great work as always man!

[romevi]

I cannot believe I'm seeing something like this so soon. The 55g is my daily work horse. To give it something to make it stand out is a delightful dream of mine.
The Digilog case is out of my reach, and I wasn't too impressed by the colors. I am so ecstatic for this GB, however, because of the options and more-updated design.

Sorry if I missed it, but will there be options for the top of the case? I remember there was a poll and you asked for options on what to put up there. I remember entering a wood finish with grooves for writing utensils, etc.

[___q]

Wow it's beautiful, would be 100% in for a GB regardless of material.

[nmur]

I now have the anodized aluminum case prototype in hand, and I couldn't possibly be happier. This is also the first time I've made a design for something involving substantial amounts of reverse engineering where I managed to nail all the details on the first try. Everything lines up and fits perfectly.

Frankly: I really, really like how this turned out. Radii everywhere, and visible seam! Totally worth the fuss.

Show Image

Show Image

Show Image

Show Image

Show Image

Show Image

Show Image

I'm now sending the verified design to the Corian manufacturer to see if they can pull off this design in that material. If that falls through, however, I'm delighted to observe that aluminum makes for a fantastic option. In that latter scenario, we could have a group buy rolling in just a couple of weeks.

Note that this doesn't have the PCB and magsafe cable. Those are on the way soon hopefully.

Also I've shown it here with the risers installed. Unlike the original RF itself, It can also be used dead flat (my own preferred orientation).

I look forward to hearing what you all think!

dude that is MINT

you've outdone yourself here, i'm so hyped for this

[exitfire401]

I cannot believe I'm seeing something like this so soon. The 55g is my daily work horse. To give it something to make it stand out is a delightful dream of mine.
The Digilog case is out of my reach, and I wasn't too impressed by the colors. I am so ecstatic for this GB, however, because of the options and more-updated design.

Sorry if I missed it, but will there be options for the top of the case? I remember there was a poll and you asked for options on what to put up there. I remember entering a wood finish with grooves for writing utensils, etc.

As someone who owned a digilog for a very long time, you aren't missing out. The quality of the breakout board was sub-par, the anodizing scratched if you looked at it funny, and the feet were awkward as hell. This looks amazing though. I'm super excited for this design. It's gorgeous.

[lasermild]

I now have the anodized aluminum case prototype in hand, and I couldn't possibly be happier. This is also the first time I've made a design for something involving substantial amounts of reverse engineering where I managed to nail all the details on the first try. Everything lines up and fits perfectly.

Frankly: I really, really like how this turned out. Radii everywhere, and no visible seam! Totally worth the fuss.

Show Image

Show Image

Show Image

Show Image

Show Image

Show Image

Show Image

I'm now sending the verified design to the Corian manufacturer to see if they can pull off this design in that material. If that falls through, however, I'm delighted to observe that aluminum makes for a fantastic option. In that latter scenario, we could have a group buy rolling in just a couple of weeks.

Note that this doesn't have the PCB and magsafe cable. Those are on the way soon hopefully.

Also I've shown it here with the risers installed. Unlike the original RF itself, It can also be used dead flat (my own preferred orientation).

I look forward to hearing what you all think!

WOW  :eek:
Perfect for my RF55g..