JP01 - Arisu Custom CNC Aluminum Unibody Keyboard Case
https://youtu.be/O6BLock8iVU ⬅ First build complete and timelapse video!
https://youtu.be/mfLEsenbGh8 ⬅ Typing test for the first build!
This repository all assets needed to manufacture a custom high-quality CNC milled unibody keyboard case for the open source Arisu PCB
_. I'm very pleased how the first prototypes came out and I'm documenting the entire process here.
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<a href="https://raw.githubusercontent.com/overset/JP01/master/V1.1/images/build5.jpeg"><img src="https://raw.githubusercontent.com/overset/JP01/master/V1.1/images/build5-lg.jpeg"></a>
CAD screenshots:
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<td width="33%"><img src="https://raw.githubusercontent.com/overset/JP01/master/V1.1/images/cad_case_ortho.png"></td>
<td width="33%"><img src="https://raw.githubusercontent.com/overset/JP01/master/V1.1/images/cad_switch_plate_ortho.png"></td>
<td width="33%"><img src="https://raw.githubusercontent.com/overset/JP01/master/V1.1/images/cad_base_plate_ortho.png"></td>
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More images from the first complete build (Not renders but an actual build Show Me The Build!
_):
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<td><a href="https://raw.githubusercontent.com/overset/JP01/master/V1.1/images/build2.jpeg"><img src="https://raw.githubusercontent.com/overset/JP01/master/V1.1/images/build2-sm.jpeg"></a></td>
<td><a href="https://raw.githubusercontent.com/overset/JP01/master/V1.1/images/build3.jpeg"><img src="https://raw.githubusercontent.com/overset/JP01/master/V1.1/images/build3-sm.jpeg"></a></td>
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<td><a href="https://raw.githubusercontent.com/overset/JP01/master/V1.1/images/build7.jpeg"><img src="https://raw.githubusercontent.com/overset/JP01/master/V1.1/images/build7-sm.jpeg"></a></td>
<td><a href="https://raw.githubusercontent.com/overset/JP01/master/V1.1/images/build8.jpeg"><img src="https://raw.githubusercontent.com/overset/JP01/master/V1.1/images/build8-sm.jpeg"></a></td>
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<td><a href="https://raw.githubusercontent.com/overset/JP01/master/V1.1/images/build5.jpeg"><img src="https://raw.githubusercontent.com/overset/JP01/master/V1.1/images/build5-sm.jpeg"></a></td>
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Test assembly and parts:
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<td><a href="https://raw.githubusercontent.com/overset/JP01/master/V1.1/images/g_case_plate.jpeg"><img src="https://raw.githubusercontent.com/overset/JP01/master/V1.1/images/g_case_plate-sm.jpeg"></a></td>
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Arisu PCB
_ layout which I find to be close to perfect and build a case that can do it justice. Once I saw the Arisu PCB
_ layout I knew what I needed to doIf you want to dive right into the models using OnShape: JP01 - CNC Unibody Case - Arisu Keyboard V1.1
_
Check out Assets
_ If you want to explore models in other CAD platforms
How do I get this now?
Risks
_Tutorial on Ordering Parts
_There are several prototype cases for the Arisu PCB in the works by some very talented individuals, but the challenge of building one from scratch to meet my design aesthetic was all too enticing.
What I'm looking for in a keyboard and why I think the Arisu layout is a worthwhile investment:
| Unibody case | No ugly seam to look at. Minimal fillet and small radii for a specific aesthetic. Simpler design to limit the number of individual parts to get CNC milled.
| Dimensions | 359mm wide, 142mm deep, 31.9 mm high on back, 22mm high on front | This is Very similar to stock Arisu case
| Weight ~4lb
| Typing angle 5 degrees
| Flat baseplate | Original design is for a flat base plate that is slightly recessed into the case. I have incorporated my logo into the design with a 0.5mm depth and a 0.25mm fillet on the top edge
| Switch plate
| Deck height
| Gaskets (Optional) | These are optional but I designed them to help with acoustics with the priority on silencing. I'm still experimenting with the multiple gaskets, switch plate metals and switch+keycap combinations.
Use these files at your own risk*
Arisu PCB v1.1
_ for gerber files
CNC milled unibody Case
case.step </V1.1/case.step>
_ STEP file for the casecase-drawing.pdf </V1.1/case-drawing.pdf>
_ drawings for the caseCNC milled base plate
base.step </V1.1/base.step>
_ STEP file for the base platebase-plate_drawing.pdf </V1.1/base-plate_drawing.pdf>
_ drawings for the base platelaser-cut switch plate
switch-plate.dxf </V1.1/switch-plate.dxf>
_ DXF file for use with laser-cutting servicesmachine cut gasket kit for sound dampening (optional)
gasket_base-plate.dxf </V1.1/gasket_base-plate.dxf>
_ gasket that covers the entire inner surface of the base plate and fits in the case flange to help with sound dampening.gasket_case-foam-dampener.dxf </V1.1/gasket_case-foam-dampener.dxf>
_ this is for the case cavity to fill with sound dampener such as EVA foam and is placed in the base between the base plate and PCBgasket_pcb.dxf </V1.1/gasket_pcb.dxf>
_ for cutting out a layer of dampener between the switch plate and PCB.gasket_switch-plate.dxf </V1.1/gasket_switch-plate.dxf>
_ for a thin layer of silicone between the switch plate top of the case. Do not go over 0.5mm thickness.(Optional) If you would rather get a laser-cut base-plate and not go with CNC for cheaper
base-plate_laser-cut.dxf </V1.1/base-plate_laser-cut.dxf>
_4x M2.5x0.45 10mm stainless steel countersunk machine screws (I prefer hex)
8x M2.5x0.45 6mm stainless steel head cap machine screws (I prefer hex)
This is a rough outline of specific vendors I used for the first prototype and should not be treated as an explicit step by step guide. There is great monetary risk with this project and I am not liable for anything you do with this information - see Risks
_. I have no affiliation with any of the vendors mentioned here and the only bias I have is that I'm pleased with what I've received so far.
The first item to get manufactured was the Arisu PCB v1.1
. I used the release assets (gerber files) from Arisu PCB v1.1
and had them manufactured by JLCPCB. Here are a few notes on that process:
The most substantial part of the project was the CNC milling order for the case parts - specifically the "case" and "base plate". I opted to use 3DHubs. The ordering process was easy and here are a few notes on the process:
They accept the .step files for both the "case" and "base plate" through their online quoting tool
I created a single order for 2 parts: "case" and "base plate"
The "case" model did not automatically pass their "Manufacturability Analysis" calling for review on "Thin walls" check but did this was not flagged anywhere else in the process
I opted for 6061-T6 aluminum on both parts
For the "case" part
For the "base plate" part
I uploaded the exhaustive drawings for each part
It took 2 days for an affiliate in the 3DHubs network to pickup the work
It took 15 days from order being placed to receiving parts at my door even while opting for longest 20day lead time
The switch plates I opted to use a laser-cutting service SendCutSend. They specialize in metals and do not offer finishing services beyond brushing as of this writing.
The gaskets were ordered from Ponoko which can cut EVA foam and Silicone of various thickness. These are very much optional and I have yet to test them
First build complete and timelapse video here: https://youtu.be/O6BLock8iVU
Typing test for the first build here: https://youtu.be/mfLEsenbGh8
Some details on the build:
TODO
| Again, Why? | I really like the Arisu layout and there is no easily accessible high quality case available for it that meets the aesthetic I was looking for or is something that would be attainable without waiting months if not years. Also: the challenge of building a custom case from scratch
| Why not build another Alice clone case or buy one of r/mm? | None of the recent group buys for custom Alice-clone cases have really hit the mark for me aesthetically. I have no doubt the build quality on some, if not all of them, far exceeds this - but the recent surge of interest has made access to join GBs prohibitive. The more recent Prime_E and Rukia come to mind and look amazing. When getting into that price point I'm looking for very specific things such as: a number row (which the Prime_E doesn't have but the upcoming PrimeKB Meridian will have), Arrow keys are a must (not on the Alice or Rukia and no number of custom layers or HJKL bindings are going to save that for me)
| RGB? ISO? Rotary Encoders? Extra B? | No, No, No and No
| But it's not symmetrical like the Alice, why waste your money? | This actually does not bother me at all. Having spend so many years on 75%, TKL and Fullsize keyboards I've always had the majority of keys on the right side. I just expect it and if it's too symmetrical it doesn't feel right to me. Even the Alice is not perfectly symmetrical
| When is the GB? | Right now, I do not intend on running a GB myself. I'm licensing the work here in a way that does not prohibit it. If you want to run a group by or one on derived work and use OnShape do consider their ToS. Also, add a reference for this and the amazing work from FateNozomi for the original Arisu keyboard. I'm happy to consult as my time allows on derivative work - it's at the heart of opensource after all
| Any modifications required to the Arisu PCB? | None. This is designed around the stock Arisu v1.1 PCB.
| Will you sell me one for $100 | No
| How much will this cost? | Low volume CNC work is cost prohibitive, but not astronomical. This varies greatly depending on manufacturers selected, finishes chosen, etc.
| Where is the wrist rest?
| See TODO
_
| Why OnShape and not Solidworks, Fusion360?
Wrist rest! I have a stacked acrylic prototype that I'm already using and love. I have a design for laser-cut solid maple with a leather top to fit perfectly with the case design. I might consider a solid polycarbonate version in the future similar to many other designs I've seen in the community and update this project appropriately
CNC simplification and cost cutting
Add more through bolts to the base plate for an even more secure design. The 4 bolt pattern is still more than enough
Consider raising the deck height of the top of the case from 7mm to 7.5 to account for proper clearance of standard keycaps. The 7mm design was originally built to incorporate a 0.5mm silicone gasket to help dampen sound, but this might not be desirable for some.
Make the USB port hole a little more centered and the access hole smaller. Possibly add a chamfer, fillet, etc to the USB port more visually appealing
Experiment with adding more material to the baseplate to bring it parallel with the PCB and minimize the volume of open air inside the case. The intent would be to benefit acoustics and add more weight to the keyboard. I'm very satisfied with the gasket dampener kit as part of the original design for helping with the acoustics
Test more base plate materials such as various brass, copper, polished stainless, etc. I've started a new OnShape branch for this at JP01 - CNC Unibody Case - Arisu Keyboard brass baseplate
_
Add another switch plate screw near the bottom right corner to prevent extra flex when pressing on the right arrow key. This was not even noticeable with the 1.6mm brass, copper, titanium or 6061-T6 aluminum plates I was testing with but would make it closer to perfect
This design should work with Polycarbonate and getting a prototype milled is on the list
Explore finishing options for switch plates (i.e. PVD)
Clean up OnShape project, unused Sketches, add variables for typing angle with constraints, make easier to export parts, optimize drawings
Bumpons
This case was inspired by FateNozomi's Arisu PCB
_ and Arisu Case
which was inspired by Lyn's EM7 and the fabled TGR Alice. This is referred to as the "open source Alice with arrows" and now with a solid unibody case.
.. _Arisu PCB: https://github.com/FateNozomi/arisu-pcb .. _Arisu PCB v1.1: https://github.com/FateNozomi/arisu-pcb/releases/tag/v1.1 .. _Arisu Case: https://github.com/FateNozomi/arisu-case .. _JP01 - CNC Unibody Case - Arisu Keyboard V1.1: https://cad.onshape.com/documents/bcb4cb10db076c215d5ca4fc/v/7ff105b1797076ce3c73421d/e/f137899a1015e62802e .. _JP01 - CNC Unibody Case - Arisu Keyboard brass baseplate: https://cad.onshape.com/documents/bcb4cb10db076c215d5ca4fc/w/63b0d2c4951fb2905cf2d82a