Keyboard Cap Design Project¶

Abstract¶

This hands-on project guides you through the process of designing and creating your own customised keyboard cap using digital sculpting and 3D printing. You'll learn how to produce a keycap for your mechanical keyboard, and then add your own design on top of the keycap. This project blends creativity, digital modeling, and practical prototyping.

What You Will Learn¶

• How to design your very own customised keyboard cap for most keyboards
• Techniques for digital sculpting and modeling in Nomad Sculpt and/or Fusion 360
• Preparing and slicing models for 3D printing
• Basics of 3D printing and post-processing

What You Will Need¶

Course Outline¶

Chapter 1: Model the keycap using Fusion 360 or equivalent CAD software¶

• Overview of keyboard cap anatomy and MX stem compatibility
• (For advanced students) Measure and recreate an existng keycap and ensure it fits the provided keyboard
• (For intermediate students) Model and recreate the keycap using the given mechanical drawing

Chapter 2: Add design to the keycap using various tools¶

• Make use of AI model generators to help creating a design for the keycap
• Use Nomad Sculpt to create and edit designs
• Import the keycap stem created in Chapter 1, and the combine with the design created in Nomad Sculpt.

Chapter 3: Preparing for 3D Printing¶

• Optimisation for 3D printing
• Exporting STL files from your modeling software
• Importing into slicer
• Configuring print settings for small, detailed parts
• Previewing and slicing the model
• 3D print

Chapter 4: Post-Processing and Finishing¶

• Removing supports and cleaning the print
• Sanding and smoothing surfaces
• Painting and finishing
• Assembling and testing the keycap on your keyboard

Project Steps - Adapting the Project to Skill Level¶

This project can be tailored to different experience levels, from beginners to advanced makers. Here’s how you can approach each step:

1. Creating a customised keycap¶

Objective: Build a 3D model of the key cap

• Contents:

• For Advanced Students:

• Start by carefully measuring an existing keycap using calipers or a ruler.
• Record key measurements such as width, height, stem size, and overall profile.
• Optionally, refer to a mechanical drawing or datasheet for precise specifications.
• In Fusion 360, create the keycap base using your measured dimensions or the provided mechanical drawing.
• Model the MX-style stem to ensure compatibility with your keyboard switches.
• Design a customised keycap in Fusion 360 or Nomad Sculpt and combine it with the existing keycap base.

• Export your finished model as an STL file, slice and print it, then post-process (remove supports, sand, and paint) for a realistic finish.

• For Intermediate Students:

• Use the provided mechanical drawing or reference model for the keycap stem and base dimensions.

• Model the keycap base in Fusion 360, using basic tools like Extrude.

• For Beginner/Younger Groups:

• Skip the measuring and base modelling steps. Use the pre-made keycap stem model instead.
• Focus on the creative aspects: in Nomad Sculpt or Fusion 360, create your own design, and attach it to the provided base.

Mechanical drawing of the keycap stem:

2. Design the keycap¶

Objective: Add more aesthetical or personal designs onto the keycap

In Nomad Sculpt: - Learn Using sculpting tools to create a pokemon Figure. - Import the keycap model from Fusion 360 to Nomad Sculpt. - Resize and assemble the pokemon figure with the keycap - (optional) Paint the digital model for multi-colour printing - Export the finished model for 3D printing.

3D modelling in Nomad

Import keycap model and fit the figure onto the stem

Mix and match: You can use Fusion 360 for precise fitting, then import into Nomad for sculpting details , or vice versa. This way, you get both creative freedom and engineering accuracy for your Pokemon-themed keycaps!

AI tools:

• Students can make use of AI modelling tools like Tripo AI to simplify the modelling process
• They can first generate or find a rendered image of their intended design, using tools like Gemini or ChatGPT, and then use Tripo AI to generate the model.
• Then import to Nomad Sculpt and edit the model.
• This can allow students to create more complicated designs and experience using AI to optimise workflow.

This is a generated Snorlax Image by ChatGPT

We can then use it to generate a 3D model in Tripo AI

In most cases AI generated models are flawed, we can then import it to Nomad Sculpt and fine tune it with the built-in tools

These are the edited designs in Nomad along with some other examples.

3. Prepare for 3D Printing¶

Objective: Export and slice the keycap model for printing.

Contents:

1. Export the finished keycap model.
2. Import the model into your slicer software (e.g., Bambu Studio).
3. Adjust orientation for best print quality.
4. Configure print settings:
5. Layer height: 0.08-0.1mm for detail
6. Infill: about 10%
7. Supports: Enable for tree support
8. Optional: Use AMS of Bambu Printers to print multi-colour prints.
9. Slice and preview the print.

Slicer preview:

4. Finish Your Customised Keycap¶

Objective: Post-process the customised keycap.

Content:

Post-Processing
- Remove the print and clean up any supports or rough edges. - Sand the surfaces for a smooth finish, especially the stem area. - (Optional) Paint the your model: - Use acrylic paint to make the model more colourful. - Add gloss or matte varnish for different effects.

Finished keycap:

1. Test fit the keycap on your keyboard. Make adjustments if needed.

Tip:
- Beginners and younger makers can focus on steps 2-4, using a provided keycap base. - Intermediate students can try with a given drawing. - Advanced students are encouraged to start from scratch, measuring and modeling the keycap base themselves for a complete engineering and design experience.

Optional Projects¶

Multi-Color Printing¶

• Use multi-color filament to print the frosting and base in different colors.

Other Themed Keycaps¶

• Design and print a series of themed keycaps (e.g., burger, pizza, sushi) for a fun keyboard set.

Keycap Display Stand¶

• Design and print a small stand to display your keycap when not in use.

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