Custom Mechanical Keyboard Build¶

Project Overview¶

A from-scratch build of a 65% mechanical keyboard featuring a custom PCB, 3D-printed case, and hand-lubed switches. This project combines electronics design, firmware programming, and a bit of woodworking for the wrist rest.

Specifications¶

Layout: 65% (68 keys)
Switches: Gateron Milky Yellow Pro (lubed with Krytox 205g0)
Keycaps: PBT Cherry-profile, dye-sublimated
PCB: Custom-designed, ATmega32U4-based, hot-swap sockets
Case: 3D-printed in matte black PLA+ with brass inserts
Firmware: QMK

PCB Design¶

The PCB was designed in KiCad 7. Key considerations:

Column-stagger layout with a dedicated encoder knob
Per-key RGB LEDs (SK6812 mini-E)
USB-C connector with ESD protection
Hot-swap Kailh sockets for easy switch changes

{
  "keyboard": "custom_65",
  "keymap": "default",
  "layout": "LAYOUT_65_ansi",
  "layers": [
    ["KC_ESC", "KC_1", "KC_2", "KC_3", "KC_4", "KC_5"],
    ["MO(1)", "KC_F1", "KC_F2", "KC_F3", "KC_F4", "KC_F5"]
  ]
}

Case Design¶

The case was modeled in Fusion 360 with a 6-degree typing angle. It uses brass M3 heat-set inserts for secure PCB mounting and has an integrated cable routing channel.

Printing Tips

Printing the case in two halves and joining with CA glue and brass pins produced much better results than attempting a single large print.

Sound Profile¶

After applying shelf liner foam between the PCB and case bottom, plus PE foam mod between the PCB and plate, the sound profile is a deep, satisfying "thock" with minimal ping.

Cost Breakdown¶

Item	Cost
PCB fabrication (5 pcs)	$28.00
Components & diodes	$15.00
Switches (70x)	$22.00
Keycaps	$35.00
Stabilizers	$18.00
3D print filament	$6.00
Total	$124.00