My New PCB’s will be here today! DHL shipping is expensive, but great when you need stuff quickly!
What this means – I should have general stock next week.
Timeline – I’ll get a test board built up this week. if that works, I’ll email out everyone who expressed an interest.
I’ll get everything kitted up through the week (time permitting) so I can get some posted this weekend.
The rest of the weekend will be spent kitting up everything I have so I can start selling again.
Sorry for the delay guys (and gals). Been a perfect storm of wrong components sent, big customs delays, non-functional PCB’s. I thought the ‘march’ timeline was generous and had plenty of padding in for worst case.
For general availability, i’ll be reviewing the price. Most things have gone up by over 20% in general (Brexit, Yaay), some have come down, and i’ve made some optimisations. These projects aren’t a get rich quick scheme for me, they’re just a way for me to get funds together to buy more tools and things to make more projects! It’s pretty much a cost neutral hobby 😛
One final update – Keycaps. I’ve started manufacturing and at the time of typing, I have sent out a few test items to kit owners. I’ll await some feedback before I can hit ‘go’ and make more.
Those are just some of the prints i’ve had to do to get to where I am now. This isn’t representative of the typical resin printing workflow. its generally a bit easier than this, BUT, I had to start from scratch, learning how to do everything, including stuff that hasn’t been done by others. AND I needed the base level print to be ‘perfect’ to avoid the need to paint them. There’s over 80 hours of actual printing time in this picture, on top of that, there’s the cleanup time, CAD time, setup time….these are the ‘successful’ failures, there’s almost as much again that i’ve binned due to total failures, where keycaps were unusuable for anything, not even experiments (as these ones have been used for). fortunatley most of those failures were caught early to avoid too much wasted resin….but when I get only 1 chance in the evenings on some days to quickly iterate, get the printer going, 1 failure can set me back a few days.
Anyways, now i’ve finalised everything……..
I’ve used an entire bottle of resin over the last couple of weeks making test manufacturing prints back to back to tune the process, changing nothing, just print, print, print… By that, I mean, it’s…
- Remove Print, clean up
- top up resin
- Cure cleaned up print
- repeat until bottle is empty
I’m now at about 70% success rate for good saleable keycaps. the other 20% have minor blotches or surface uniformity issues, so i’ll sell those discounted for those that are interested. I’m still getting about 1 in 1o that can’t be used in any way.
Good enough, and i’m sure i’ll get better as time goes on. Each print takes 6.5 hours – slow, but reliable and a 25uM layer height so about as good as it gets on resin printing for surface finish.
Each print also takes another 30 minutes or so to ‘turn around’ –
- Remove from bed
- clean bed
- set printer up again to print the next item
- clean print (1 minute soak in IPA, then 5 minutes in ultrasonic bath then another couple of minutes under a warm running tap)
- Dry Print – This is critical to good finishes. Some are taking up to 3 days, overnight in cardboard boxes near the radiator. I need to do a few checks in that time to ‘dab off’ excess moisture that leeches out of the print. Any moisture left on the tops of the keycaps alters the surface finish.
- Cure print – this takes time also. I’ve found using UV lights (wash and cure station) warps the keys more often than not. Once the caps are dry, I leave them a couple of days in the conservatory. After that, i’ll blast them for a few minutes under UV light to finish the curing
- Then it’s pack them up ready for posting!
And, Pack some up, ready for posting I have! I’ve done a mix of ‘on the supports’ and ‘loose in bags’ to see how these things go. I’ve posted a couple to myself via friends overseas to see if they survive!. once I know what i’m doing is working, I’ll make them available for sale!
8 sets of keycaps ready to go, waiting feedback from testers before I can ship!