Left final

icarus

Files pertaining to the development of my personal custom keyboard Icarus.

Ergogen

The keyboard and pcb layout were generated using Ergogen locally. The config files and corresponding outputs can be found in the ergogen folder. There are custom footprints that generate 3d models on the footprints of all components, and these are found in final_pcbs/components. The path for these are custom to my file setup, and thus will most likely not work on your machine. Please change the corresponding file paths if you wish to locally build this model.

KiCad

The corresponding PCB outputs from Ergogen were traced in KiCad. The final traced PCBs, along with exported STEP files are found in the final_pcbs folder. Currently, the final PCBs do not have the switch and keycap models on the footprints of the switches, and there are traces which have been shown to be on fragile board sections. Both of these changes will be updated in the near future and this notice will be removed once that happens.

Case files

The case files were constructed in Onshape. One can view these files here. There are also STEP files in this repo, in the case_files folder. Note that the case files provided are for the left side of the keyboard only, and the right side is simply a mirror image of the left side.

Travel case files

The travel case can be on Onshape here. Please do note that the case may take upwards of five or more (5+) minutes to load depending on your internet connection and local compute power. This is due to the high detail of the wing design on the top half of the case. For the printing process, I chose an adaptive layer height with 0.04-0.14mm layer height @0.02mm nozzle, and performed manual filament changes. I printed each quarter of the case separately, and the pins and latches separately as well. Supports were mostly normal on the slim setting, with manual painting to best suit my printer's needs and capabilities. The pins were printed @0.06mm layer height and were printed on a 3 layer raft with normal grid supports, placing them flat on their long edge (axis of extrusion parallel to the build plate). The latches were placed with the pivot holes placed normal to the build plate ("on their side"). I will not be providing the .3mf files as they are too large to upload to GH.

ZMK configuration.

Icarus currently runs ZMK. The configuration repository and current firmware can be found here.

Physical build notes

This case was designed and printed for FDM, though the battery cage is a major flaw in the design. There are supports that are best printed as "normal slim" supports on Orca, for example, as these had the cleanest release. I found that it was best to print the ports/switches/etc on the case as-is, then clean up with a file, though one may find success with adding supports and removing those manually. Additionally, I reccomend placing brim ears on all corners of the faceplate/skirt print, as well as the baseplate as they tend to warp during printing. Mounting the baseplate to the PCB was done with M2.5 self-threading screws, which need washers to secure onto the board. Print these separately, and not attached to the baseplate. There is also a known issue with the right PCB's battery jack hitting against the Kailh hotswap bracket, which will be fixed soon™. Finally, to ensure that the keys fit into the shield, one must use flush cutters on the key-side of the shield to cut the soldering joints flush. It doesn't need to be perfectly flush, but as flush as possible is best. If any other issues arise in whoever decides to build this, please reach out!