# Production

For the production I use 3D Printing for the keys and housing of them, Milling for producing the PCBs 
and Laser cutting for creating the side and bottom panels of the keyboard.

## PCB Milling

### GCODE generation
For the PCB milling I again used [mods](https://modsproject.org/).

::::{grid}
:::{grid-item}
![IMAGE](../media/final_project/pcb_outline_gcode_generation.png)
:::
:::{grid-item}
![IMAGE](../media/final_project/pcb_outline_gcode.png)
:::
::::
::::{grid}
:::{grid-item}
![IMAGE](../media/final_project/pcb_generate_gcode.png)
:::
:::{grid-item}
![IMAGE](../media/final_project/pcb_all_gcode.png)
:::
::::

I always used following parameters (\[mm\]):

|Process|Bit|Tool|Cut Depth|Max Depth|Step Over|Offset|
|-------|---|----|---------|---------|---------|------|
|Carve traces|Vbit 0.2|4|0.12|0.12|0.5|6|
|Mill away rest|Flat Endmill 0.8|2|0.12|0.12|0.5|0|
|Mill out PCB|Flat Endmill 0.8|2|0.4|1.5|0.5|1|

### Milling

![IMAGE](../media/final_project/fab_mill_key_pcb.jpg)
::::{grid}
:::{grid-item}
:columns: 7
![IMAGE](../media/final_project/fab_milling_pcb1.jpg)
:::
:::{grid-item}
```{video} ../media/final_project/attiny_mill_timelapse.mp4
:width: 100%
```
```{video} ../media/final_project/mill_xiao_pcb2.mp4
:width: 100%
```
:::
::::

### Post Process

![IMAGE](../media/final_project/fab_pcb_keys.jpg)
![IMAGE](../media/final_project/fab_pcb_post_process1.jpg)
![IMAGE](../media/final_project/fab_pcb_xiao_post.jpg)
![IMAGE](../media/final_project/fab_pcb_attiny_v1.jpg)

### Soldering

```{video} ../media/final_project/pcb_soldering.mp4
:width: 100%
```
![IMAGE](../media/final_project/fab_soldered_xiao.jpg)
::::{grid}
:::{grid-item}
![IMAGE](../media/final_project/fab_soldered_pcb.jpg)
:::
:::{grid-item}
![IMAGE](../media/final_project/fab_solder_xiao.jpg)
:::
::::

:::{note}
All soldered above were fails -.-
:::

**Final Working Boards**

![IMAGE](../media/final_project/pcb_soldered_all.jpg)

## 3D Printing

::::{grid}
:::{grid-item}
```{video} ../media/final_project/3d_print_keys2.mp4
:width: 100%
```
:::
:::{grid-item}
```{video} ../media/final_project/3d_print_keys.mp4
:width: 100%
```
:::
::::

**Testing the Mechanics**
::::{grid}
:::{grid-item}
![IMAGE](../media/final_project/fab_assamble_keys.jpg)
:::
:::{grid-item}
![IMAGE](../media/final_project/fab_test_mechanic.jpg)
:::
::::
For more testing, see [programming](./final_project_programming.md)

**Final 3D Print**
![IMAGE](../media/final_project/fab_final_3d_print.jpg)

### System Integration

For the foam to stick onto the Keys I used double sided Tesa-Tape which worked extremely good actually on the 3D print and foam.

::::{grid}
:::{grid-item}
![IMAGE](../media/final_project/fab_tape_keys.jpg)
:::
:::{grid-item}
![IMAGE](../media/final_project/fab_key_foam.jpg)
:::
::::
![IMAGE](../media/final_project/fab_pcb_sun.jpg)

Here I tested if the board will fit

::::{grid}
:::{grid-item}
![IMAGE](../media/final_project/fab_system_integration1.jpg)
:::
:::{grid-item}
![IMAGE](../media/final_project/fab_system_integration2.jpg)
:::
::::
![IMAGE](../media/final_project/fab_system_integration0.jpg)

Here I tested the fit of all boards and the snap-fits:
![IMAGE](../media/final_project/fab_screwed_pcbs.jpg)

## Laser Cutting

**Prepair**

In FreeCAD I used the 'TechDraw' Workbench to use the side of the designed models as a vector graphic.
![IMAGE](../media/final_project/freecad_svg_for_laser_cut.png)

![IMAGE](../media/final_project/fab_laser_bottom_plate.jpg)

**Cut**

::::{grid}
:::{grid-item}
```{video} ../media/final_project/laser_cut_bottom_plate.mp4
:width: 100%
```
:::
:::{grid-item}
```{video} ../media/final_project/laser_cut_side_plate.mp4
:width: 100%
```
:::
::::

I used following settings for the 6.5mm wood:
-   Power: 80%
-   Speed: 7mm/s

**Post Process**
::::{grid}
:::{grid-item}
![IMAGE](../media/final_project/fab_cutted_panels.jpg)
For the side panels I used less power and more speed to only mark the holes I later mill (not through!) with a pillar drill.\
On our drill, I even had a display and could measure the distance, what a dream. \
I also made a small countersink for the screws so the keyboard stand on an even plane.
:::
:::{grid-item}
![IMAGE](../media/final_project/fab_mill_plate_holes.jpg)
:::
::::

And afterwards I also sanded the laser-cut side so it looked a bit cleaner.

## Assembling
::::{grid}
:::{grid-item}
The I screwed down everything, placed magnets inside of the 3D print and side panels and snapped it together.
![IMAGE](../media/final_project/fab_assambled_pcb_housing.jpg)
:::
:::{grid-item}
![IMAGE](../media/final_project/fab_assambled3.jpg)
![IMAGE](../media/final_project/fab_assambled2.jpg)
:::
::::

**Final Result**

::::{grid}
:::{grid-item}
:align: right
```{video} ../media/final_project/assembly_rotated.mp4
:width: 100%
```
:::
:::{grid-item}
:columns: 4
![IMAGE](../media/final_project/package.png)
Made by [Matthias](https://fabacademy.org/2025/labs/ilmenau/students/matthias-testa/)
:::
::::
![IMAGE](../media/final_project/fab_assambled1.jpg)