Flightless Angels

The Pocket Chip is fun to play with but that keyboard is nearly unusable. I designed a magnetically attached removable replacement that goes on top of the metal domes and provides a good positive click action. I find 3D printed keys are pretty annoying and I needed space to print the key legends, so I’ve used genuine buttoncaps. They feel better and leave room for legends.

I found the PCB layout files and extracted the pad coordinates to design a keyboard. The hexagonal and round projections fit into the holes in the Pocket Chip.

Here is the print. I sanded the top and then ironed it to provide a smooth surface for the vinyl to stick to.

Here’s the underside showing the projections, the holes for the keys and the parts for the magnets.

I made a template to position the vinyl layer and let me accurately place it on the keyboard.

The keys took a lot of experimentation with different parts to get right. The top part is 100PCS For 6*6Round Tact Switch A101 Plastic Switch Button Caps from Ali Express, link here. The inserts are Fastex 207-080551-00 Plastic Plug 1/8 Hole Round Head. They fit together to make a solid key with a good click feel.

Here’s the populated keyboard. You can also see the magnets used to hold the keyboard onto the pocket chip. At the bottom of the image are retaining bars which, once glued in place, stop the keys from falling out.

Here’s the completed unit. I glued magnets onto the underside of the board, and between those and the round/hexagonal inserts.