Making keycaps out of polyamide

[adhoc]

So it has come to my attention I have an old friend of mine who can do practically anything from polyamide. All he needs is 3D model, the rest is done by a machine with a laser melting dust layer by layer. Colours are not a problem and from what he tells me colours do not wash away with time.

Now my question is - anybody has any experience with polyamide keycaps?

If anybody has 3d models of keycaps I'm inviting you to send me them, so I can print a few keys from this plastic and test out the durability on them! Can be topre or MX!

[damorgue]

Several people have made caps through additive manufacturing. The issue with them is you have to make a test block with a few stems to see exactly what specs will fit the best since there are variations between machines and techniques and the fittings has very high tolerances.

[adhoc]

Yeah we know we would have to go through several iterations, producing a perfect 3D model won't be any easy task anyway...

[matt3o]

what's the definition of the printer? do you have samples?

[M'er Forever]

[Account and posts deleted on request]

[adhoc]

The thing is he can do ANYTHING. He works in a EU funded company which got top-notch 3d printers. High polish is included in the manufacture. I have got a 3D model and sent it to him, he will create a few caps and I will reiterate the 3D model if need be to perfection. Will keep this thread updated!

Now the durability part...I have no idea! This is what I want to test out!

EDIT: I don't know the printer type nor have any samples. I should have a sample key cap very soon, though.

[M'er Forever]

[Account and posts deleted on request]

[adhoc]

Yes, STL is preferred. I do have lots of software options to convert, but am best with Catia (well I'm a Abaqus pro, but it's really not appropriate for design).

[M'er Forever]

[Account and posts deleted on request]

[adhoc]

No worries, I can handle AutoCAD. And proengineer. And.....in EU, you have to know all the software there is + at least 5 different languages + all the maths, physics and mechanics as a mechanical engineer to work for minimum wage. Just sayin'...

[M'er Forever]

[Account and posts deleted on request]

[adhoc]

So, here they are. Only the "skull" ones fit. I'm going to 3D scan a cherry cap for the surface to get a fitting key without the skull on top (this was just a test for the square that fits on the switch). The rest are unusable because a) they don't fit and b) they have a flat surface, but this was just a test to see what would work, what would it look and feel like and whether they're even viable. As for the plastic goes it feels a lot like PBT to the touch and this can be fine adjusted later down the road with more or less polish, of course.

Opinions?

[adhoc]

Oh just so nobody gets this wrong - I am NOT trying to fake CCs or something like that. I downloaded 3D models that already had these skulls on top so I simply printed the caps to check which stems actually fit the best.

[matt3o]

it's pretty neat, but the layering is disturbing. I believe there's a technique (acetone bath or something) that helps removing some of the stripes coming from the 3d printing process.

[adhoc]

Yes, there are ways to remedy that, but this was just a test run. Dimensions have been updated in a 3D model now and I want to make a cylindrical cap that fits perfectly. Then I will try to get some colors into them and only then start thinking about how to give the surface a more polished look - if the plastic turns out to be enough durable!

It's a fun little side project, will keep this thread updated. If nothing else, I might try making a few out of aluminium as well.

[Muirium]

Aluminium sounds very interesting to me:

Because with custom made caps, there are a world of alternatives to explore…
http://deskthority.net/news-reviews-f4/ ... t7166.html

[adhoc]

Well the means to do it are there, but right now I need a "bullet-proof" 3D-model. I think this one might be it, but we will see. The problem with plastic is a completely different animal than with metal, since I have means to create very accurate metal objects (2-3 microns I believe). We'll see, if everything pans out fine and there will be interest from others, I might take some orders with individual design requests and whatnot, but I don't want to talk too quick as there's a whole bunch of stuff that need fixing first and I need to find out if the price will be worthy.

[Muirium]

Indeed. I'd love a set of engraved aluminium or brass (looks great and is cheaper) caps, made to my exact layout and profile someday. But the devil is in the details. Every last one of them!

[matt3o]

btw, I doubt those keycaps are alu... anyway I'll try to make a test with metal powder, if the key doesn't come out too brittle it might be an easy and relatively cheap way to have metal looking caps.

[adhoc]

I'm an engineer, I know all about the details, don't you dare talk to me about the details, DON'T YOU DARE!

Hah, we will see. I need to make a few phone calls and spend some more time with design. Will keep this thread updated!

[Muirium]

Good! We'll be here.

btw, I doubt those keycaps are alu... anyway I'll try to make a test with metal powder, if the key doesn't come out too brittle it might be an easy and relatively cheap way to have metal looking caps.

I know they're not, but I'd quite like metal caps in that retro futurist style. Or metalled caps, if you can pull those off at quality!

[adhoc]

BUMP!

New test batch from ABS, it was terrible and very expensive, oh well. Lesson learned. It was good enough for testing out how to colour them and stuff like that, the quality in the end was still HORRIBLE.



Then I went back to PA and got the model pretty much perfected now;



The Superman keycap is just perfect, feels just like my ABS, the fit is great etc. I will work around removing layers even finer now and how to add nice colours to the caps. Will keep this thread updated

(P.S.: I've been using PA caps for some time now (~1 month) and they are actually great, they don't discolour, break or anything like that, so this might be viable material! Will see!)

[kint]

If the white caps in your post are what you're heading at, then go make them thicker. You know, as solid as possible. Not out of durability issues but enthusiast like them that way. Just sayin'. Otherwise looking gooood

[adhoc]

Good suggestion! I will definitely work on thick caps for next batch, which should run this week

[bhtooefr]

How about Alps mount?

[adhoc]

I had Topre in plan first after Cherry, since I have one at home, but sure Alps is also not off the table at all.

[adhoc]

Bumpity bump!

ALPS - might need some work, don't have a keyboard to test it out at the moment anyway (if anyone is ready to lend me a cap and/or a switch or even better - both, please PM me);



And then the almighty topre;




What do you think?

[Muirium]

Neat!

Alps is pretty tough to get right. It's a tight fit at the best of times. I have some spare Alps (actually modern Matias) switches and caps. Do I get a cool custom Alps prototype in return?

[adhoc]

Deal! But some patience would be required as I've got seriously a lot of things going on right now in parallel so it might take a while before I get to actually do it. Next 2 weeks I'm busy at 100% so I'm going to start working on caps again after that time.

Ugh, everything takes so much time when you're trying to do achieve something in your spare time

[damorgue]

Looks familiar