geekhack
geekhack Community => Keyboard Keycaps => Topic started by: crbr on Fri, 20 November 2015, 16:43:58
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I am becoming very curious about the different ways keycaps can be made. Is there a source for information about how each kind of keycap is produced?
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They're injection molded.
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Keycap shells are injection molded.
The more interesting process is the legend printing process, for which there are several:
1. Pad printing
2. Laser etching
3. Dye sublimating
4. Double-shot molds
Sometimes a combination of the above (double-shot main legends with pad printed front legends, for example). I don't have links that describe each process in great detail.
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Keycap shells are injection molded.
The more interesting process is the legend printing process
:O Take it back! Injection molding is cool. :(
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Sorry. I only meant interesting in the sense that there is more to talk about/consider.
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Sorry. I only meant interesting in the sense that there is more to talk about/consider.
Haha, I figured as much. But I have to defend my polymer processing! :P
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What about artisan keycaps?
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What about artisan keycaps?
Yeah, I am guessing a lot of artisans are 3d printed. Is this considered injection molded? Aren't there many different plastics that can be used, and don't those plastics require different processes/heating?
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What about artisan keycaps?
Yeah, I am guessing a lot of artisans are 3d printed. Is this considered injection molded? Aren't there many different plastics that can be used, and don't those plastics require different processes/heating?
Most artisans are cast. They are thermosets, meaning they cure and are permanently in that shape.
Injection molding is thermoplastic resin that is reheated to melt it and injected to form the shape. Thermoplastics can be remelted and reformed.
Polymer chemistry is fun. :D
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What about artisan keycaps?
Yeah, I am guessing a lot of artisans are 3d printed. Is this considered injection molded? Aren't there many different plastics that can be used, and don't those plastics require different processes/heating?
Most artisans are cast. They are thermosets, meaning they cure and are permanently in that shape.
Injection molding is thermoplastic resin that is reheated to melt it and injected to form the shape. Thermoplastics can be remelted and reformed.
Polymer chemistry is fun. :D
I am familiar with injection molding, but not with casting. Would someone please explain what a keycap artisan would actually do in order to produce a keycap design using the casting technique?
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There are casting tutorials here if you search for them. Use Google search and add site:geekhack.org to the end of your search terms.
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The more interesting process is the legend printing process, for which there are several:
There is a more reading in the Keycap printing (http://deskthority.net/wiki/Keycap_printing) article on the Deskthority Wiki about regular mass-produced keycaps.
All mass-produced keycaps are injection-moulded: a plastic is melted and injected into a steel mould at high pressure and then cooled.
A full set is usually moulded at once with spouts between all caps - called a "parts tree". The individual caps are then broken off from the parts tree, leaving small marks usually situated at the back of each keycap.
I think Signature Plastics and GMK often cast smaller shots at once, though.
Most mass-produced plastic parts are made the same way. The mould and machine cost a great deal but each individual cast is cheap. That is why small runs of keycaps are more expensive and keyboards made in the tens of thousands are cheap.
I am familiar with injection molding, but not with casting. Would someone please explain what a keycap artisan would actually do in order to produce a keycap design using the casting technique?
You will be able to find lots of articles and Youtube videos if you search for "resin casting" - those should show you the basics. There are two main types of room-temperature resins: (poly)urethane and epoxy, and a large amount of varieties of each, where not every one would withstand being pounded by fingers every day.
Also, to avoid bubbles in in clear casts you would need a compressor and pressure chamber to de-gas the resin before pouring.
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It was one Christmas night, Mama ABS and Papa ABS had a little too much to drink.
Things are heating up and they fumbled and fell into the casting machine. Papa ABS decides that he didn't like the feel of the rubber (o-ring) so they decide to just go at it without it. Mama ABS and Papa ABS had a moment of intimacy and bonded together.
Few minutes after, and a double shot was born.
Son, this is how keycaps were made. Also remember to always use o-ring.
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It was one Christmas night, Mama ABS and Papa ABS had a little too much to drink.
Things are heating up and they fumbled and fell into the casting machine. Papa ABS decides that he didn't like the feel of the rubber (o-ring) so they decide to just go at it without it. Mama ABS and Papa ABS had a moment of intimacy and bonded together.
Few minutes after, and a double shot was born.
Son, this is how keycaps were made. Also remember to always use o-ring.
:)) LOL