Introduction

I have always been intrigued about the idea of making mechanical keyboards, customizing it the way you would like it to look and sound. However, there are some creativity limitations due to a small selection of barebones keyboards readily available when they run out of stock.

The purpose of this project is to apply my engineering skills into my own personal project, especially in a product that I would be able to use in my everyday life. In order to do this, I will be making a mechanical keyboard by scratch, modeling my own keyboard case for manufacturability, taking into consideration of design constraints due to weight and dimensions of the PCB/other components in the keyboard. I will also be designing my own PCB and implementing the firmware, in order to understand the ins and outs of circuit design. In the end, I hope that I will be able to create a functioning mechanical keyboard that I can use for my own personal setup.

Keyboard Case

Brainstorming process

As many keyboard enthusiasts know from the list of specifications, I am going for a thocky sounding keyboard build. Thocky is like a deep, low-pitched, marbly sound. After researching different types of materials for the case, plate, foams, etc., I came up with the list of components to include for my keyboard to achieve the desired sound. I chose the Gummy O-ring mount because it requires only one piece for the case in order to make the manufacturing process easier and cost effective. Otherwise, popular choices such as the gasket mount and the top mount would require two pieces to manufactured in comparison to one.

Different types of keyboard mounting styles

The taro60 is based of an existing keyboard, the Tofu60, due to the similar dimensions in the schematic and specifications. However, in the actual modeling process, the dimensions had to change due to the model's geometry that would not allow the original Tofu60 dimensions. Therefore, the new dimensions had to be tweaked in order for the case to be symmetrical. During the modeling process, I decided to include a steel plate at the bottom to give the keyboard a more premium look and adding a weight will affect the sound slightly. This is because adding the weight will affect the resonance and vibration characteristics of the entire assembly.

3D Modeling in SolidWorks

3D model of keyboard case in SolidWorks

Orthographic projections of taro60 v1.0

Steel plate including engraving of milk tea design

Bottom view of taro60 v1.0 assembly including steel plate

Polycarbonate taro60 v1.0 final assembly exploded view

Next steps

Once I figure out the dimensions of where the USB-C cutout will go in the back of the case and the silicone rubber feet at the bottom to prevent slipping, I will 3D print the case in ABS for the first prototype to ensure the PCB and dampening foams will fit inside the case before manufacturing it into either aluminum or polycarbonate. Currently, I am starting on the PCB design.

Updates

1.22.26: Constantly redesigning the case due to some constraints. The pictures do not depict the final design but rather the early stages of the design. There are some issues with the extrude cuts not matching the typing angle and other dimensions/geometries that need to be fixed. The current design is different compared to these images. I am still working on the PCB design on top of redesigning the case.

WIP: PCB Design, Manufacturing

stay tuned! (˶˃ o ˂˶)𐭩🧋