HHKB USB Blockers

[nubbinator]

I've got way too many little projects going on, but this one popped into my head today and I wanted to get a mock-up cranked out.

I love my HHKB.  I never thought I'd become hooked on it, but I am.  Despite that, there are little quirks about it that bug me.  The one that got to me today was the fact that you have such a nice, clean looking board that covers up dip switches and has these ugly naked and exposed USB ports that I almost never use.  I looked at USB blockers, but they all are these ugly blocks that don't flow into the case design.  So I took some measurements and came up with this:






I erred on the side of caution, so I may have to make some parts a little thicker, but I think the basic concept is sound.  They may pop out if you're slinging the board around, but should stay in place for the casual user.  I plan on getting some made up and going from there.

[FLFisherman]

Looks promising to me. I just try to pretend those slots aren't there (but deep down I knooooow).

[Bambino]

Why not have an insert into the USB port? Would keep them in there more securely.

[whmeltonjr]

Cool idea. Is that the color you're making them in?

[raymogi]

Woohoo can't wait to see how this goes. I've been wanting this for so long as well.

[nubbinator]

Why not have an insert into the USB port? Would keep them in there more securely.

I may add a small flange that goes into the first mm or so, but the main reason I didn't is that I want it to be relatively easy to remove.  With something going into the port, you need some sort of handle so you can pull it straight out.  If I get the tolerances right, it should fit in snug without any issues though.

Additionally, I plan on doing this in resin and very few pigmentable resins are strong enough structurally to go into the USB housing.  The absolute last thing I'd want is for the blocker to break off in the USB port.  If fitment becomes an issue, even after trying a flange, I can always mod and encapsulate some cheap USB blockers into the design.

Cool idea. Is that the color you're making them in?

Probably one of them.  I'll get it made in a transparent medium since it holds detail better and is stronger, then cast some.

[alexjd99]

Do you plan on making the files available so we can print some if we have a printer?

[nubbinator]

Trying out 3Dhub for the masters of this.  I found someone a bit cheaper than Shapeways with what should be a higher resolution print. 

I looked at my HHKB again and realized I may have messed up on the inner assembly a little and oriented it to the slope instead of the flat back. 

Do you plan on making the files available so we can print some if we have a printer?

I may after I recoup my investment costs.  I tend to prefer to pop the files on Shapeways though.

[nubbinator]

Prototypes are in the mail and should arrive Tuesday.

[Bromono]

oooo can we get them in cool colors too

[nubbinator]

oooo can we get them in cool colors too

That's the plan.  When I get making some caps again, I think I'll probably hack them included on all Topre cap sets.


If they work well, it may finally give me an excuse to do a benchtop injection mold machine so I can crank them out.  There may have to be a slight redesign though since I'm not sure they'd pop out of a hard two piece mold easily.

[geniekid]

Why not have an insert into the USB port? Would keep them in there more securely.

I may add a small flange that goes into the first mm or so, but the main reason I didn't is that I want it to be relatively easy to remove.  With something going into the port, you need some sort of handle so you can pull it straight out.  If I get the tolerances right, it should fit in snug without any issues though.

Additionally, I plan on doing this in resin and very few pigmentable resins are strong enough structurally to go into the USB housing.  The absolute last thing I'd want is for the blocker to break off in the USB port.  If fitment becomes an issue, even after trying a flange, I can always mod and encapsulate some cheap USB blockers into the design.

Also, people using Hasu's custom controller don't have USB ports at all (outside of the normal mini-USB one).

[nubbinator]

Got them the other day.  They're close, but I need to do some editing.

[FLFisherman]

Got them the other day.  They're close, but I need to do some editing.

The sizing was a bit off?

[nubbinator]

Just barely on the small side.  I was conservative since printing usually ran big for me.

They do fit and work, just not as snug as I would like.

[whmeltonjr]

Other than size being slightly off, did they look like you envisioned?

[flabbergast]

I would love something like this for my HHKB (also with hasu's controller, so no actual USBs there, just holes).

[Bromono]

Did you use shapeways, and if you did, is it obvious that they are 3d printed?

[nubbinator]

I used 3dhub since it was far cheaper and a much better print.

[nathanrosspowell]

They look great. I have been meaning to 3D print some that are compatible with the Hasu controller. Here's a model by alienman82 https://www.reddit.com/r/MechanicalKeyboards/comments/36npbh/i_3d_printed_usb_covers_for_the_hhkb_with_hasu/crfvnx3

[alexjd99]

They look great. I have been meaning to 3D print some that are compatible with the Hasu controller. Here's a model by alienman82 https://www.reddit.com/r/MechanicalKeyboards/comments/36npbh/i_3d_printed_usb_covers_for_the_hhkb_with_hasu/crfvnx3

I wish these worked on a stock HHKB. Just printed one out, and the little insert is just barely too long to fit in there. I guess I'll have to modify the stl so that it'll fit

[nubbinator]

Well, apparently posting a link that gives you a $10 discount on $25 and gives me a little discount on future purchases is not allowed.  If you want to try out 3DHub, shoot me a PM and I can send you the link.

[nubbinator]

Sending out for revision 2 soon.  I, stupidly, didn't save an unchamfered one, so I'll have to do some hand sanding in the corners.   I've trying two revisions here.




Changes made: 

1. slightly increased width and length to fit it more snugly into the case.  It's already clean looking, but I want some friction fit.

2. longer USB hole plug.  It wasn't deep enough and the revised version reaches the USB connector.

3. on half of them added a little bit to add a little friction to the fit in the USB cutout


Mods changed their tune on the referral link since it should give you a discount and give me credit:

http://3dhubs.refr.cc/78SLRMC

I used Apex.  They primarily do dental stuff, but they were cheap and the resolution of their prints is fantastic.  I would gladly use them again and plan on doing so as long as they remain affordable.

If a couple people use the link I posted, I'll be open sourcing the files as I work on them since it will offset my research costs.  You will need a very high resolution printed to make them though.