I've been trying hard to figure out a working combination of switches and key caps. I really don't want to use the normal tactile switches that so many old synths use. They wear out over time and the travel is very short.
Where I come from - IT - (and in the rest of the world I guess), mechanical keyboards are all the rage. Incidently, I used Cherry ML switched (and concidered Cherry MX) when I did the Machinebeats drum machine more than 10 years ago, long before Cherry MX became THE keyboard key. I even had a Cherry keyboard in the 90s. But I digress. What I'm saying is I want to use a proper switch, rated for millions of clicks.
The problem is keycaps. While Cherry do/did sell some non-keyboard keycaps, they are still square and keyboard-looking. That's why I want to create my own keycap. But 3D-printing the tiny mounts used for the various switches is not a very good option, especially with a filament based 3D-printer.
My idea is to use a commonly available keycap and mount MY part on top of that. That gives a much bigger surface to glue things to. However, getting a completely flat keycap seems almost impossible.
I'm considering four different switches: Cherry ML, Cherry MX low profile, Kailh Choc and Kailh Choc V2. The MX low profile seems really hard to find, but I've ordered the Kailh variants for testing.
After a few failed attempts, some nice, almost flat Kailh Choc caps arrived from Ali Express today. I immediately tried filing them down using some 180 grit sand paper. And voila! It looks great! The cap height went from 0.13" to 0.12", and now it's completely flat. Great Success! Only issue is the cap is ABS, so I can't laser cut the outline.
I'm still waiting for the switch. I've also ordered some round, flat-looking caps for the Choc V2, but it seems like I have a good option for the Choc so I might as well go with that.
On a separate note - using black keys was a really good idea, it is very easy to see when I have filed it down enough to be flat :-D
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