The Zatarra Mark I [deprecated] - A Series of Geometric 60% Keyboard Cases

UPDATE (August 22, 2020): The Zatarra Mark I has been superseded by the Zatarra Mark II.

This is a series of 60% keyboard cases. My goal in creating these cases was to experiment with different variations on the traditional tray mount style. Variation Nos. 1-4 reflect these different mount systems. In contrast, the differences among Variation Nos. 5-13 are merely cosmetic. (All of the latter use a ledge mount system.) Finally, I've included three badges that you can add to the top bezel of any of the variations. To add a badge (or badges) to a case, you will need to boolean-subtract the badge mount from the case model. [The badges are re-mixed versions of models that were posted by other people to Thingiverse. I will fix this post to add the proper attributions as soon as I can.]

N.B. I have not printed out any of these cases yet, so cannot give any assurances about whether they feasible or printable. I have, however, printed out the Haydee case (https://www.thingiverse.com/thing:4344723), which is similar to the ledge mount variations here. That print was largely successful, but was ever-so-slightly small. The plate and PCB fit, but a few of the keycaps in the upper-left and lower-right rub against the case. Therefore, depending on your printer setup, you may need to print these cases at slightly larger than 100%. The ledge mount, however, works as intended.

Variations:

• No. 1 (Ledge Mount): This variation contains a 5 mm ledge running around the inside of the tray, which supports the PCB in lieu of standoffs.
• No. 2 (Standoffs): This variation contains all of the standard 60% PCB standoffs except the center standoff.
• No. 3 (Empty Tray): This variation does not have any supports for the PCB. Instead, the PCB rests directly on the bottom of the tray. If you use this version, I'd recommend putting foam on the bottom of the tray.
• No. 4 (Integrated Plate): This variation incorporates an integrated plate generated by the swillkb plate and case builder. Note that this variation is split into a top half and a bottom half. N.B. I tried printing out a test plate using the swillkb builder, but the switch cutouts were slightly small. So, you may need to experiment with print size. Further, as modeled, this case will require significant supports to print out. Eventually, I plan to change the xy plane cut to align with the bottom of the plate, move the mount pegs to the bottom half, and move the mount holes to the top half, to reduce the need for supports.
• No. 5 (2mm Radius Fillets on All Outside Edges): This variation uses a ledge mount system.
• No. 6 (3mm Radius Fillets on All Outside Edges): This variation uses a ledge mount system.
• No. 7 (4mm Radius Fillets on All Outside Edges): This variation uses a ledge mount system.
• No. 8 (4mm Radius Fillets on Outside Top and Side Edges): This variation uses a ledge mount system.
• No. 9 (3mm Chamfers on All Outside Edges): This variation uses a ledge mount system.
• No. 10 (4mm Chamfers on Outside Top and Side Edges): This variation uses a ledge mount system.
• No. 11 (Topology Optimized): This variation was created by passing Variation No. 1 through Autodesk Fusion 360's topological optimization algorithm.
• No. 12 (4mm Radius Fillets on Side Edges): This variation uses a ledge mount system.
• No. 13 (4mm Radius Fillets on All Outside Edges, Length Reduced): This variation is identical to No. 7, but is shorter along the x-axis by a total of 2mm. I ran into problems fitting No. 7 onto my build plate, even though the print should theoretically fit, so I shortened the case by a one millimeter on each side.

UPDATE (August 5, 2020): Added Variation No. 13.

Category: Electronics