Beamspring Factory process - How to
Posted: 16 May 2019, 16:24
Hi,
I am making a thread to document my construction of new beamspring keyboards/components. I will collect designs, files and processes here. I wish to be able to make all the components of beamspring keyboards because why not. Thus I will do this.
I have worked with wcass and DMA bouncing ideas off of them as well as them helping in many ways. Obviously they have both been a big help and I couldn't have gotten this far without them.
Main imgur collection here. I find imgur difficult to use. So duplicates etc will occur.
https://imgur.com/gallery/x0B4aZV
https://imgur.com/a/mrZbist
So far I have managed to produce a cherry mx conversion for my 3278 into a 60% Ansi Keyboard.
(I have DSA "ice" keycaps now to replace the space and modifiers I borrowed from a quckfire. I know they look bad)0
Most keys do not actually need the stabilizers as beamsprings almost never bind. I have been adjusting the 3d printed stems in order to get the stabilizers to work well. https://imgur.com/bBQUrR5 https://imgur.com/aCJ01Hi
Costar stabilizer bent bars hit the return spring and are not the best.
PCB/Metal cut gerbers
These are my first pcbs. As such they do not follow any particular good design rules for pcbs. They should 'work' but they aren't elegant, or really well thought out. I can't guarantee they will work, so if you order one from a pcb maker I suggest you double check it. Obviously I have uploaded them so you can change them etc. I have opted so far to use 2 layer PCBs because they are easier to make. They use the DMA commonsense controller on an external board because it is easier to test with an external controller. These are works in progress.
From what Ive found and learned from wcass.
https://imgur.com/Yy11gH3
https://imgur.com/IwOjOw8
This style of PCB is possibly the "first" beamspring style pcb. It has many vias which were expensive to produce. The sensing pads are both on the front of the pcb, the "rows" as they were travel using vias and connected to a trace on the back. There is also a massive amount of grounding copper rows on the back.
I theorize that the "front and back" style of PCBs that are seen in later Beamspring and then Model F keyboards are a cost saving measure. As such I opted to produce a PCB which is more akin to the original and hopefully has very strong signalling.
I made an MPCNC machine to make new metal plates. I have only cut some balsa wood ones so far as I just made the machine. I will eventually attempt to use aluminium.
For the plates I have found that having a very thin 3d printed card with the "tabs" to align the keys, makes it easier to machine the plate as you need no tabs on the plate.
ansi board - 60% board
Uses mostly original keys except for space modifiers etc using cherry mx stems for those.
https://imgur.com/uVy1nQq
https://imgur.com/eh1pliL
https://imgur.com/XhMJYPZ
https://imgur.com/gWW6Otx
https://imgur.com/PCRSdSG
Model M style
I haven't actually ordered this made yet but will be doing so soon.
https://imgur.com/M79FRCu
https://imgur.com/V1yFxuf
https://imgur.com/Zst6hOx
https://imgur.com/rW9FZSH
Conversions so far have been straight forward. As you need a plate and a pcb along with the DMA controller. You can then use original switches/caps etc.
I wish to be able to DIY/DIWHY produce all components of beamsprings so I can fill out my Model M variant.
For the production of new components I am less developed.
Return Spring
Currently I am working to perfect a 3-piece 3d printed plastic stick screw. I have music wire of 0.025 inch thickness.
I have been able to wrap the wire around the stick to make new return springs. This is somewhat time consuming but it works.
The stick has 3 lengthwise pieces. The 2 outer ones have the screw guide and the middle one doesn't. I will upload this file soon.
What you do is wrap the wire around and then remove the middle stick to remove the other pieces, and there you go new return spring.
Here is a basic idea of the mechanism. It is a guide to get the winding right, and then it disassembles.
https://imgur.com/a/gWKzwPS
I will update on the progress of these springs this weekend.
*This system didn't work at all. I have been able to make some decent springs by using a makeshift brake out of 2 metal plates, a bolt/nut and wood with music wire. Must continue developing.
Foot
For the switch plate foot, black carbon 3d printed plastic seems to work somewhat. It is obviously capacitive. It doesn't matter what you make the barrel assembly out of.
I will be uploading some OBJ/STL files later tonight. The main consideration for this part is whether or not it should have a stem on it. The reason this is a question is that the original flyplate was press fit onto the foot with a metal backward fork preventing removal. I would rather use a small screw as if I am going to make flyplates, I would rather just punch out one hole in the middle with maybe 2 position post circles.
The stem can be seen in this gallery which will upload fully soon.
https://imgur.com/gallery/Jx1lnxF
Flyplate
This piece will have to be stamped somehow. I believe the easiest way would be to order a circuluar disc puncher. As the metal is 0.035 inches thick. I would then bend it on a fixture that is 3d printed.
I have been in contact with this etsy seller of custom punches. They have quoted me between 150-350 usd. I am attempting to make one of these out of aluminium currently. Even if the aluminium punch only lasts a few punches, I think it would still be cheaper to keep remaking these.
https://www.etsy.com/ca/listing/6248648 ... rket&frs=1
Beamspring - Reasonable Reproduction Achieved
For the beamspring itself, the steel is 0.015 inches thick spring steel and you can cut it with scissors. (Don't ask me how I know this.)
The beamspring itself "should" be reasonably easy to make.......... with a press as it is just a shape with a hole in the middle. Just like the flyplate, I am currently trying to source/perfect my punch press in order to make larger quantities of new springs.
Barrel Assembly
I will upload an obj/stl of this a bit later. It is a pretty straight-forward geometric object that can be 3d printed.
Keycaps
I have done a lot of research about the beamspring keycaps. They are cool. I believe that were you to try to make a production beamspring board today, the largest single expense would be the keycaps and it would quite likely take up a massive majority of the cost. As such I am not attempting to do this at this time aside from experiments.
Basic work in progress 3d models for plastic parts.
https://www.thingiverse.com/thing:3641754
I will continue to update this post in the future with files etc. Let me know if you have any questions or input.
I am making a thread to document my construction of new beamspring keyboards/components. I will collect designs, files and processes here. I wish to be able to make all the components of beamspring keyboards because why not. Thus I will do this.
I have worked with wcass and DMA bouncing ideas off of them as well as them helping in many ways. Obviously they have both been a big help and I couldn't have gotten this far without them.
Main imgur collection here. I find imgur difficult to use. So duplicates etc will occur.
https://imgur.com/gallery/x0B4aZV
https://imgur.com/a/mrZbist
So far I have managed to produce a cherry mx conversion for my 3278 into a 60% Ansi Keyboard.
(I have DSA "ice" keycaps now to replace the space and modifiers I borrowed from a quckfire. I know they look bad)0
Most keys do not actually need the stabilizers as beamsprings almost never bind. I have been adjusting the 3d printed stems in order to get the stabilizers to work well. https://imgur.com/bBQUrR5 https://imgur.com/aCJ01Hi
Costar stabilizer bent bars hit the return spring and are not the best.
PCB/Metal cut gerbers
These are my first pcbs. As such they do not follow any particular good design rules for pcbs. They should 'work' but they aren't elegant, or really well thought out. I can't guarantee they will work, so if you order one from a pcb maker I suggest you double check it. Obviously I have uploaded them so you can change them etc. I have opted so far to use 2 layer PCBs because they are easier to make. They use the DMA commonsense controller on an external board because it is easier to test with an external controller. These are works in progress.
From what Ive found and learned from wcass.
https://imgur.com/Yy11gH3
https://imgur.com/IwOjOw8
This style of PCB is possibly the "first" beamspring style pcb. It has many vias which were expensive to produce. The sensing pads are both on the front of the pcb, the "rows" as they were travel using vias and connected to a trace on the back. There is also a massive amount of grounding copper rows on the back.
I theorize that the "front and back" style of PCBs that are seen in later Beamspring and then Model F keyboards are a cost saving measure. As such I opted to produce a PCB which is more akin to the original and hopefully has very strong signalling.
I made an MPCNC machine to make new metal plates. I have only cut some balsa wood ones so far as I just made the machine. I will eventually attempt to use aluminium.
For the plates I have found that having a very thin 3d printed card with the "tabs" to align the keys, makes it easier to machine the plate as you need no tabs on the plate.
ansi board - 60% board
Uses mostly original keys except for space modifiers etc using cherry mx stems for those.
https://imgur.com/uVy1nQq
https://imgur.com/eh1pliL
https://imgur.com/XhMJYPZ
https://imgur.com/gWW6Otx
https://imgur.com/PCRSdSG
Model M style
I haven't actually ordered this made yet but will be doing so soon.
https://imgur.com/M79FRCu
https://imgur.com/V1yFxuf
https://imgur.com/Zst6hOx
https://imgur.com/rW9FZSH
Conversions so far have been straight forward. As you need a plate and a pcb along with the DMA controller. You can then use original switches/caps etc.
I wish to be able to DIY/DIWHY produce all components of beamsprings so I can fill out my Model M variant.
For the production of new components I am less developed.
Return Spring
Currently I am working to perfect a 3-piece 3d printed plastic stick screw. I have music wire of 0.025 inch thickness.
I have been able to wrap the wire around the stick to make new return springs. This is somewhat time consuming but it works.
The stick has 3 lengthwise pieces. The 2 outer ones have the screw guide and the middle one doesn't. I will upload this file soon.
What you do is wrap the wire around and then remove the middle stick to remove the other pieces, and there you go new return spring.
Here is a basic idea of the mechanism. It is a guide to get the winding right, and then it disassembles.
https://imgur.com/a/gWKzwPS
I will update on the progress of these springs this weekend.
*This system didn't work at all. I have been able to make some decent springs by using a makeshift brake out of 2 metal plates, a bolt/nut and wood with music wire. Must continue developing.
Foot
For the switch plate foot, black carbon 3d printed plastic seems to work somewhat. It is obviously capacitive. It doesn't matter what you make the barrel assembly out of.
I will be uploading some OBJ/STL files later tonight. The main consideration for this part is whether or not it should have a stem on it. The reason this is a question is that the original flyplate was press fit onto the foot with a metal backward fork preventing removal. I would rather use a small screw as if I am going to make flyplates, I would rather just punch out one hole in the middle with maybe 2 position post circles.
The stem can be seen in this gallery which will upload fully soon.
https://imgur.com/gallery/Jx1lnxF
Flyplate
This piece will have to be stamped somehow. I believe the easiest way would be to order a circuluar disc puncher. As the metal is 0.035 inches thick. I would then bend it on a fixture that is 3d printed.
I have been in contact with this etsy seller of custom punches. They have quoted me between 150-350 usd. I am attempting to make one of these out of aluminium currently. Even if the aluminium punch only lasts a few punches, I think it would still be cheaper to keep remaking these.
https://www.etsy.com/ca/listing/6248648 ... rket&frs=1
Beamspring - Reasonable Reproduction Achieved
For the beamspring itself, the steel is 0.015 inches thick spring steel and you can cut it with scissors. (Don't ask me how I know this.)
The beamspring itself "should" be reasonably easy to make.......... with a press as it is just a shape with a hole in the middle. Just like the flyplate, I am currently trying to source/perfect my punch press in order to make larger quantities of new springs.
Barrel Assembly
I will upload an obj/stl of this a bit later. It is a pretty straight-forward geometric object that can be 3d printed.
Keycaps
I have done a lot of research about the beamspring keycaps. They are cool. I believe that were you to try to make a production beamspring board today, the largest single expense would be the keycaps and it would quite likely take up a massive majority of the cost. As such I am not attempting to do this at this time aside from experiments.
Basic work in progress 3d models for plastic parts.
https://www.thingiverse.com/thing:3641754
I will continue to update this post in the future with files etc. Let me know if you have any questions or input.