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Thread! Here's a writeup of something I've been wanting to try for a long time, a qwerty handheld with custom-designed silicone keyboard. The display used is the @pimoroni 4" 720x720 square "HyperPixel". It's still an early non-functional prototype but I think it has potential!pic.twitter.com/kC1HxHG6MX
I created a script to generate png files with parametric size for the overall size, the size of the display, the size, spacing and amount of the keys. I then imported that into @adskFusion360 and 3d printed a frame.pic.twitter.com/gIRbTD2FNZ
For the keyboard, I used a clear acrylic mold milled by @timonsku (who also helped with the design ). I took a video of the casting process so the next photos will be frames from the video.pic.twitter.com/9XMdcrsX0y
The silicone used is the @SmoothOn Dragon Skin 20 transparent silicone, it comes in two parts that you mix 1:1. Overall it worked great, but I think 20 shore hardness is still too low and I will need to purse something with higher hardness. Good enough for a proof of concept.pic.twitter.com/hOQIW9E1tb
I used a @JesmoniteLtd black pigment to color the silicone, 3 drops were enough for such a small amount. It worked great with the silicone, doesn't rub off and is very uniform.pic.twitter.com/CwTCbwqGJx
Then I used the jar+food vacuum degassing hack by @jrsikken, the pot life of this silicone is 25 minutes so I degassed for 20. The silicone still had some bubbles in it but it was better than not doing it. In the future, I'll probably look into something a bit more pro.pic.twitter.com/96xw65pOGJ
After screwing together the two mold parts, I used a baster syringe (lol) to inject the silicone. It worked surprisingly well! The cleanup was also really easy, after the silicone cured, I just pulled it out leaving a clean syringe.pic.twitter.com/QKE85x3Hhs
And there you have it. For now, it's just a case with a screen and keyboard, there is no functionality. the next steps are to design a PCB with metal domes so I can verify the mechanical design.pic.twitter.com/8bHWFzhwRg
Other things to figure out include finding a way to print labels on the keys, ordering bare screens (already found a seller), and making a board that actually does something. I acquired a @TechNexion module with @nxp i.MX7 on it so I can easily iterate low-cost base boards!
Here's @timonsku's thread on the milled mold:https://twitter.com/timonsku/status/1221453449373589504 …
I should also try and throw the mold into a tumbler so it can smooth out the routing paths a bit, you can see them in the final silicone. It's not a big deal but would be interesting to see if it's possible to get rid of that.
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