I’ve been playing around with cutting some holes for Alps switches on a CNC router. I’m starting with MDF, but once I get a few designs figured out I’ll use some nice hardwood, cut the other side of the wood so there’s space for hand wiring, and make a bottom case as well.
Anyway, there are a few things wrong with this prototype: I forgot to rotate the switches for the 1x1.5 keys, the dimensions are just slightly too tight so I had to whack the switches with a rubber mallet to get them into place, and I don’t think the overall design is quite right yet.
But it was still a useful morning, and I think the general idea will work pretty well.
Front view:
Top view:
Side view:
With one of the switches removed so you can see the hole:
With a switch in the hole:
I used a 1/8" end mill to cut everything, because that’s the only tool I currently have. Before I get to producing a usable keyboard, I’ll probably get some other tools to cut the bulk of the material out faster, and make the final shapes with a bit finer detail.
I’d also like to see if I can cut keycaps.
