Dani 75 Hand Wired Keyboard Design Guide

Overview:
Welcome to the guide for building the Dani 75, a 75% hand wired keyboard utilizing a USB-C clone of the Pi Pico microcontroller, powered by KMK firmware. This guide aims to provide clear instructions for assembling and customizing your own version of this keyboard design.
(I may add my firmware files later)

Hardware and Components:

• Pi Pico microcontroller clone (USB-C)
• Keyboard components (switches, keycaps, diodes, etc.)
• Plate mount stabilizers
• Threaded inserts and M2 screws (M2x8, M2x12, M2x20)
• Your preferred gasket material (I utilized a roll of foam cut to size for optimal fit)
• Soldering iron (or alternative bonding materials)
• Hot glue gun

Assembly Instructions:

• Print Parts: Utilize the provided STL files to 3D print the keyboard parts. I used around 15% infill for the case and 25% for the plate to make it sturdier, but feel free to adjust. Note: The plate may be challenging to print if your printer has adhesion issues; a glue stick may be necessary.

• Join Parts: The printed parts can be joined using a soldering iron or adhesive material of your choice.

• Gaskets: Place gaskets on top and bottom of the plate

• Place Switches in Plate: Before soldering, place the switches in the plate. Friction fit should be tight but may need some filing if your printer is not dimensionally accurate

• Solder Keyboard Matrix: Solder the keyboard matrix however you please. Many tutorials are available online. If using a microcontroller compatible with kbfirmware.com, you can visualize the matrix design process, but please note that generating KMK firmware for a Pi Pico is not supported on this site.

• Microcontroller Mounting: Affix the Pi Pico microcontroller to the designated spot on the keyboard base using hot glue. Ensure a secure fit.

Ideas for Improvement and Remixes:

• Microcontroller Compatibility: While designed for the Pi Pico clone, other microcontrollers may be compatible with minor adjustments to the USB cutout.
  Screw Size: Consider upgrading to M2.5 screws or larger for improved durability and ease of use.

• Joining Method: Explore alternative methods for joining parts together, such as a layered design so that screws can be used to join the left and right halves in place of soldering or adhesives.

Mounting Method: The board was fairly stiff despite the gasket mount, I would consider a tray mount for simplification of the design and ease of assembly.

I hope you can enjoy building and tinkering with this board as much as I have.