As [Glen] describes it, the only real goal in his decision to design his single-key USB keyboard was to see how small he could build a functional keyboard using a Cherry MX key switch, and every fraction of a millimeter counted. Making a one-key USB keyboard is one thing, but making it from scratch complete with form-fitting enclosure that’s easy to assemble required careful design, and luckily for all of us, [Glen] has documented it wonderfully. (Incidentally, Cherry MX switches come in a variety of qualities and features, the different models being identified by their color. [Glen] is using a Cherry MX Blue, common in keyboards due to its tactile bump and audible click.)
[Glen] steps though the design challenges of making a device where seemingly every detail counts, and explains problems and solutions from beginning to end. A PIC16F1459, a USB micro-B connector, and three capacitors are all that’s needed to implement USB 2.0, but a few other components including LED were added to help things along. The enclosure took some extra care, because not only is it necessary to fit the board and the mounted components, but other design considerations needed to be addressed such as the depth and angle of the countersink for the screws, seating depth and clearance around the USB connector, and taking into account the height of the overmold on the USB cable itself so that the small device actually rests on the enclosure, and not on any part of the cable’s molding. To top it off, it was also necessary to adhere to the some design rules for minimum feature size and wall thicknesses for the enclosure itself, which was SLS 3D printed in nylon.
PCB, enclosure, software, and bill of materials (for single and triple-key versions of the keyboard) are all documented and available in the project’s GitHub repository. [Glen] also highlights the possibility of using a light pipe to redirect the embedded LED to somewhere else on the enclosure; which recalls his earlier work in using 3D printing to make custom LED bar graphs.