[COMPLETED] Laser Cut Prototyping mini-GB

[matt3o]

• 1x mirror steel trim layer of 1.5 mm
• 1x aluminium plate layer of 1.5 mm*
• 3x aluminium case layers of 3mm
• 1x mirror steel base layer of 1.5mm

Corrections welcome!

The following would be better:

• 1x mirror steel trim layer of 3 mm (1.5mm would be really small, but that's up to you, maybe 2mm is the safe spot?)
• 1x aluminium plate layer of 1.5 mm
• 3x aluminium case layers of 3mm
• 1x steel base layer of 1.5mm

If you want you could have the base done in mirror. It depends on how many people join the GB. If we have just 3/4 orders it would be like ordering them singularly, we would pay full price but you could order whatever material/thickness you like.

*You said this about 1.5 mm aluminium in your Brownfox build thread:

The aluminum plate is 1.5mm thick, but I have the feeling that I could have done it 2mm for better stability. Next time I might try that. I had a similar keyboard done in steel and keys stick better on 1.5mm steel than they do on 1.5mm alu. Steel is too stiff though and typing is a bit tiring.

Have you changed your mind about 1.5 mm aluminium's feel?

No, I haven't but I did not test the 2mm thickness myself while the 1.5mm I'm sure it works. I would have to make a test first, but you know, they are expensive tests.

[Muirium]

Wise as always.

I'm thinking I can get the upper trim and the base cut from the same sheet (or leftover) for symmetry's sake and perhaps a bit of cost saving. I'd be perfectly happy with a super heavy base! 1.5 mm of each also works, I think.

Got a picture of Steely's steel and Brownfox's aluminium right next to each other, viewed from the side? Because those two shades will be what these design decisions are all about.

[matt3o]

Aesthetically speaking Steely kicks Brownfox ass really hard! If we could anodize the aluminum it would be a different story. I'll try to ask if we can anodize aluminum.

[Muirium]

Mmm… steely.

I still wouldn't mind trying Steely's plate out for look and feel. PM me about shipping if you like.

[matt3o]

I asked about anodized alu. It's very cheap if we anodize before cutting, if we anodize after the cut it costs x5.

speaking of $$$ it would be +€5/kg or +€15-20/kg

[pasph]

I asked about anodized alu. It's very cheap if we anodize before cutting, if we anodize after the cut it costs x5.

speaking of $$$ it would be +€5/kg or +€15-20/kg

not bad

[photekq]

Just out of curiosity if I had 2 or 3 of my plate made would it be cheaper per plate? I'll most likely only want one but if I can save some money per-plate by getting 2 or 3 I'd be interested.

[matt3o]

depends how many orders we get. There doesn't seem to be a high interest in this, it's likely that we will be paying full price for each piece

[photekq]

depends how many orders we get. There doesn't seem to be a high interest in this, it's likely that we will be paying full price for each piece

I see. Well, regardless of the price, put me down for 2 of my plate.

[matt3o]

I've updated the first post with the order list. The laser cutter closes all August, so we will be probably placing the order at the beginning of September, even though I'd like to start this sooner. If there's not enough interest, I'll simply close this Sunday and send the order for the three of us this Monday.

[photekq]

I've updated the first post with the order list. The laser cutter closes all August, so we will be probably placing the order at the beginning of September, even though I'd like to start this sooner. If there's not enough interest, I'll simply close this Sunday and send the order for the three of us this Monday.

Hmm.. If this gets extended to September then I'll have to drop out. I need these plates by the start of August at the latest.

[matt3o]

if we place the order this Monday, you should get them the first week of August.

[photekq]

if we place the order this Monday, you should get them the first week of August.

That would be fine.

[bueller]

I can hopefully let you know how 2mm goes as I'll be getting my plate cut with that in the next couple of weeks.

[photekq]

2mm will work fine with the switches, however it will not work with costar stabilisers. You will need to use cherry stabilisers.

Costar spec is 0.06" (about 1.524mm iirc - so costars work with 1.5mm)

[matt3o]

2mm will work fine with the switches, however it will not work with costar stabilisers. You will need to use cherry stabilisers.

Costar spec is 0.06" (about 1.524mm iirc - so costars work with 1.5mm)

glad to hear that switches work on 2mm!

costar could always be filed and then glued.

[photekq]

Hmm, actually I'm not too sure about 2mm now that I think about it. 0.06" is also cherry's spec for the switch plate. If it does work it'd be good though.

[bueller]

2mm will work fine with the switches, however it will not work with costar stabilisers. You will need to use cherry stabilisers.

Costar spec is 0.06" (about 1.524mm iirc - so costars work with 1.5mm)

Cheers for the info, I think I'll go with 1.5mm then for my first board. Will try 2mm in future but for my first custom I'd rather not deviate from Matt3o's plan too much.

[matt3o]

I'm also trying to have the alps plate on 1.5mm instead of the suggested 1-1.2mm... crossing fingers

[pasph]

How many complete cases we need for a price drop?

[matt3o]

I believe we won't see any price drop before 20 layers (not cases)

[Muirium]

20/5=4. But we're talking about 20 layers from the same sheet aren't we? I can use 3 when it comes to case sides. Perhaps 4, if my base is the same stuff.

Oh, Matt, about that PDF? (My ancient Illustrator can't open your file.)

[Zifle]

I'll have to get in on this as well.

What would the price of the following be?

Plate, in 1.5mm alu
Bottom of case, in steel (thickness doesn't matter too much to me, so whichever is easiest)

Also, if you don't mind, could you go over the dimensions quickly? Specifically the stabilizer holes, I've simplified my design, so it'd probably be a good idea to make sure those fit.

[matt3o]

I'll have to get in on this as well.

What would the price of the following be?

Plate, in 1.5mm alu
Bottom of case, in steel (thickness doesn't matter too much to me, so whichever is easiest)

Also, if you don't mind, could you go over the dimensions quickly? Specifically the stabilizer holes, I've simplified my design, so it'd probably be a good idea to make sure those fit.

that would be probably €60 for the plate and €25-30 for the bottom, but this is just a very rough estimate.

stab holes seem fine. You probably converted from inches to mm but everything seems fine.

[pasph]

Can you estimate the cost (full price) for a case with a plate like this

steel bottom and alu for the rest?

[matt3o]

Can you estimate the cost (full price) for a case with a plate like this

steel bottom and alu for the rest?

that should be around 110-130 for the whole case if we do not reach the critical mass to get a discount. Yes, all alu + steel bottom.

[Zifle]

that would be probably €60 for the plate and €25-30 for the bottom, but this is just a very rough estimate.

stab holes seem fine. You probably converted from inches to mm but everything seems fine.

Sounds good, sign me up.

[pasph]

Can you estimate the cost (full price) for a case with a plate like this

steel bottom and alu for the rest?

that should be around 110-130 for the whole case if we do not reach the critical mass to get a discount. Yes, all alu + steel bottom.

Can someone please design that plate+case for me?

[matt3o]

I may try to help you with that. I'd need ISO return specs though (basically stabs position). Also, it would be a new case design and each new case would require prototyping.

[Zifle]

Can you estimate the cost (full price) for a case with a plate like this

steel bottom and alu for the rest?

that should be around 110-130 for the whole case if we do not reach the critical mass to get a discount. Yes, all alu + steel bottom.

Can someone please design that plate+case for me?

I made a quick markup, but it'll have to get checked, especially the iso enter. I took an educated guess, and placed the hole in the middle of the cap, but I have no idea if that is correct. I'd assume the stabs are fine, but they should definitely also get checked before actually getting used.

You'd also want to evaluate the spacing between the sections on the left. I used 10mm, I imagine you might want less.

dxf