Three platforms. Three engineering approaches.
Premium CNC production → human-centered electromechanical design → accessible additive manufacturing
A configurable CNC platform, manufactured for customer builds.
I translated customer preferences into a CNC-machined 6061 aluminum case and plate, a brass mass element, and a mounting architecture that tunes the same enclosure for different typing responses.
Four mounts. One chassis.
Top, bottom, gasket, and O-ring configurations change plate boundary conditions, compliance, vibration transmission, damping, and keypress feedback without replacing the enclosure.
Mass informed by users.
Community demand guided the brass weight. Its higher density than aluminum redistributes mass and changes vibration response; geometry and interfaces also shape acoustic character and perceived solidity.
A faceted internal chamber.
Stepped, non-parallel surfaces change reflection paths and cavity response while removing material. PCB and switch clearance, mounting interfaces, wall thickness, fastener access, and CNC tool access remain design constraints.
CAD through production.
I resolved cutter geometry, machining access, fits, fastener interfaces, tolerances, assembly order, and cosmetic finishes through design reviews and vendor communication, then coordinated customer assembly and QC.
Material Experimentation
I built and evaluated plates and enclosures across metals, composites, sheet polymers, and FDM materials. Stiffness, density, damping, surface hardness, anisotropy, and process quality all influenced structural response, acoustics, typing feel, durability, and manufacturability.
Control the build
I varied plate and case materials in A/B configurations while holding switches, PCB, mounting configuration, fastener preload, and assembly method consistent; keycaps, geometry, and operating conditions were matched where practical.
Repeat and compare
Repeated assembly and typing evaluations separated persistent material-dependent behavior from build variation. I compared compliance, rebound, local flex, vibration transmission and decay, resonance character, pitch, and acoustic sharpness against mass and interface behavior.
Include production behavior
I assessed surface durability, finish and edge quality, dimensional repeatability, tolerance stability, machining or printing effort, warping, layer anisotropy, and assembly fit alongside cost, scalability, and user feedback.
- 01Material selection→
- 02Controlled build→
- 03Structural / acoustic evaluation→
- 04User feedback→
- 05DFM review→
- 06Design iteration
Material library
Build observations and selection tradeoffs—not instrumented material-property measurements. Choose a category, then browse the cards.
Browse with the arrows, scroll horizontally, or drag / swipe. Comparisons depend on geometry, interfaces, and print settings.
Engineering the response
No material is universally best. Plate stiffness, enclosure mass, damping, mounting constraints, cavity geometry, and interface behavior interact; I selected materials for the intended product response and production process.
| Design intent | Material direction |
|---|---|
| Premium enclosure | 6061 aluminum |
| Targeted mass / visual accent | Brass |
| High stiffness at low mass | Carbon fiber |
| Compliant plate | POM · polycarbonate sheet · FR4 |
| Accessible printed case | PLA · PETG |
| Durable engineering parts | Nylon / PA |
| Compliant interface | TPU |
From CAD to product
- 01User requirements→
- 02Concept→
- 03CAD packaging→
- 04Material selection→
- 05DFM & tolerancing→
- 06Manufacture→
- 07Assembly & QC→
- 08User feedback→
- 09Iteration
I owned consultation and requirements gathering, custom CAD, component sourcing, outside-vendor manufacturing coordination, assembly, and quality control. Design reviews and user feedback connected machining and print constraints to the behavior of delivered hardware.
Across the business, I served 100+ customers and generated $10K+ in revenue. Published open-source hardware designs and build documentation reached 5,000+ people, extending the work into repair, modification, and community iteration.