A500 Mini Keyboard – D’oh! More work needed

Nah, that looks crap.

Well, that’s a wrap for idea 1 – concept was ok enough, but…it’s no-where near good enough for a production run.

After half a dozen trial prints and practice fittings, I’m heading down another path.

The Many faults include

Keys fitting poorly to switches.

Keys not fitting on switches straight

Keys just not fitting onto switches at all

The attached picture sums it up really.

All is not lost however. This is something I had to trial, if it worked, it would have been cheaper and awesome.

I have a few ideas up my sleeve…My next option is right now, considerably more expensive, but has been underway for a few weeks now, I’ll reveal a bit more once the process is done.

On the plus side, the keycaps look great in Amiga Beige! – I’ll work on the darker caps another time.

The PCB layout works great, firmware works, so, really, it’s down to the thing that always was going to be an issue, the switches!

Dodgy Laptop Hinges – Lenovo Ideapad 5 15″Model 15ARE05

Nearly two years ago, I purchased a rather nice laptop – https://www.lenovo.com/gb/en/laptops/ideapad/500-series/IdeaPad-5-15ARE05/p/88IPS501393

A Nice Lenovo 15″ beastie, with a Ryzen 4800U

I blogged a bit about it right – HERE

Just after Christmas, one of the screen hinges snapped – I had a quick google, then really did nothing – I found thhis bloke –

It’s Binh Repaired & Reviewed

and, this video

https://www.youtube.com/watch?v=jQ3YShJosio

and, as the laptop was functioning ok-ish, I dismissed it – it was robust enough to use, and wasn’t properly broken….

…Until it was –

A couple of weeks ago, both hinges just failed, leaving my laptop screen ‘dangling’

So, I googled again, discovered that I’m not alone. Most people seem to jab a bit of JBweld in and hope for the best

https://forums.lenovo.com/t5/General-Discussion/Broken-Hinge-on-IdeaPad-5-15IIL05-Laptop-Type-81YK/m-p/5063546?page=4

https://www.bogleheads.org/forum/viewtopic.php?t=369644

I didn’t have any JBweld.

I Did however have the following items, which, after years of desperately needing a project to justify the purchase have Finally come in useful and saved some cash

Ingredients

……. a Portable Dremel thingy,

a wide collection of tiny drill bits

boxes of tiny screws and nuts.

A ridiculously small adjustable spanner on my car keys

My laptop no longer has a non-functional Hinge

Have a small Montage of pictures

To Be fair to Lenevo – they’re extremely responsive for customer support. I can not fault their technical team, nor their customer support team, pro-active calls, checkups and emails, all in, a 5* Lenovo response…..

with one caveat, My laptop’s out of warranty. Still, for most, a quick hundred quid ain’t too bad a price to fix a £500 laptop properly!

A500 Mini – part 8 – partly working keycaps and a small PCB reveal

First working keyboard keycaps are off the printer!
Only this bit to show as most of the print failed 😛

Well,, 3 prints failed, I’m trying to learn how to use my Photon Mono-X, so far mostly unsuccessfully, these were printed using a known good combination of Photon Mono and Commodore Brown resin 🙂 ….and still it partly failed!!

Next, I have to optimise the design for printing.
I’d added some features to make them work better, but, those features don’t translate to printing very well, D’oh! (That’s called not doing Design For Manufacture!).

Resin printing can be a hard beast to tame, especially when printing 94/98 individual items (98 if I can two keyboard types!!)

This first print is literally an ‘auto supports, Jab a few extras on, hope for the best’ quick test to prove the mechanics.
When the design is finished,
I’ll need to spend a couple of solid DAYS (maybe a weeks worth of evenings) adding thousands of supports MANUALLY to ensure every keycap comes off the print perfect!

That sounds a lot, but printing a single item is different than printing the same item hundreds of times, so it’s really worth the up front investment in time.

And, speaking of time, I’ve just clocked about 600 hours evenings and weekends, on this project now 😛

I’m rather happy otherwise, next week, I should have a full working keybaord to demonstrate 🙂

Another failure
Another failure!

And, the reveal, part 2

It’s here!!!!

A500 Mini II Part 7 – other ‘stuff’

Along the way, I’ve been tweaking some other bits – The Real miniature fake USB Floppy disc is progressing nicely

IT FITS!!

I’m on the second design of the 3D Printed insert, this will hold the USB PCB and also be the interface and guide rails for the floppy.

I’ve also received my memory solution for the discs, it fits superbly! – it can be seen in the badly printed / broken green area. The dimensions are exactly the same as the 3D print i’ve put in

I’ve also purchased some silver brushed effect sticky foil so I can re-create that beloved silver cover….and even have created the label ready to cut out on my dusty KNK ZING vinyl cutter thingy. Hopefully I can make the adhesive sticky enough!

A Floppy fits in the drive!
Tiny

The silver ‘label’

I’ve also started stocking up on Printer resin, ordered a load of sample parts from Aliexpress, test fitted PCB’s…..started on box design, started tweaking firmware, there’s dozens of tasks to do!

A500 Mini II Part 6 – past the half way mark! – keycaps

Quite a lot of progress, but it doesn’t look like a lot of progress.

Firstly, I’ve had to re-do most of the keyboard CAD – I simply didn’t like the ‘blocky’ effect of the wider topped keycaps I’d created – as you can see below they look a lot more square in real life than they did in CAD…

I’ve now clocked well over 200 hours developing this set of keycaps, likley there’s going to be tens more tweaking / optimising!

So, along with the less blocky (more slopey) keys, I’d discovered my workflow in CAD had created tapered keys – the tops when viewed from above look like parallelograms, wheras the original Amiga had more square keys – it was quite a lot of work to alter this – see the parts below by the red arrows – the bottom bit is in towards the middle more than the top bit.

Tops not parallel with bottoms
Tops are parallel with bottoms
Continue reading “A500 Mini II Part 6 – past the half way mark! – keycaps”

A500 Mini Keyboardification Chapter two, part 4 – Moar CAD

Have been tweaking things over and over, I’m now finally ready to…….

3D Print a sample!
And, the complete thing

I think there’s going to be a few people out there actually using this keyboard in anger, so i’ve widened the keyswitch tops a little and added larger fonts to make it easier for someone to fill in some colour if they chose to do so.

Some other progress –

The Floppy Disc insert! – a FULL scale floppy disc fits well

I’ve refined the floppy disc insert thingy – I really think I can make this work – lots of parts on order so i’ll iterate this design over the coming weeks. I’ll do the first prints of the plug in module soon

Alternate View – with the Clamp PCB in black, the A500Mini PCB in green

Speaking of prints….

I knocked up a few of the mini-Floppies. Printed in various orientations to see if it’s even possible to do these. The best print is the angled one..Turns out, it’s going to be tricky as can be seen from the various failures above. Have re-designed a little and will run off some more sample prints soon. The supports on this one will be critical and hopefully not so wasteful as the C64mini keycaps were.

And, almost finally –

Here’s a collection of ‘stuff’ rendered so far. The Keyboard PCB is unfortunatley upside down – due to the way I started modelling stuff, no big deal but makes the renders look odd. The case slopes don’t need to be modelled (at this time) so i’ve just left them flat for now.

There’s loads of parts waiting to arrive in the post, but there’s also loads I can be getting on with, not just on this project, but on numerous others also!