CUSTOM ERGONOMIC SPLIT

KEYBOARD

ELECTRONICS & COMMUNICATION ENGINEERING

By Hardik Sharma
Reg. No. 311101046

GOVT. COLLEGE OF ENGINEERING &

TECHNOLOGY, JAMMU

DEPARTMENT OF ELECTRONICS & COMMUNICATION

ENGINEERING

JAMMU 181 122, J&K, INDIA

AUGUST - 2024
 ACKNOWLEDGMENTS

It is our proud privilege and duty to acknowledge the kind of help and guidance received
from several people in preparation of this report. It would not have been possible to prepare
this report in this form without their valuable help, cooperation, and guidance.

Secondly, we must express our sincere heartfelt gratitude to all the faculty members of the
E&C Engineering Department who helped me directly or indirectly during this course of
work.

Last but not the least, we wish to thank our parents for financing our studies in this college
as
well as for constantly encouraging us to learn engineering. Their personal sacrifice in
providing this opportunity to learn engineering is gratefully acknowledgement.

- Hardik Sharma
 LIST OF TABLES

Table No. Table Title Page No.

2.1 A Traditional Flat Keyboard (HJ SNAKE AL75) 39

LIST OF FIGURES

Figure No. Figure Title Page No.

2.1 A Traditional Flat Keyboard (HJ SNAKE AL75) 13

2.2 A Wrist Rest 14

2.3 An Ergonomic Keyboard (Akko ACR Pro Alice Plus) 15

2.4 A Fixed Split Keyboard (Record Alice) 18

2.5 An Adjustable Split Keyboard (Lily58) 18

2.6 A Tented Split Keyboard (Corne Cherry) 19

2.7 ErgoDox EZ 19

2.8 Kinesis Freestyle 20

2.9 Moonlander 20
3.1 Staggered Keyboard Layout 21

3.2 2 A Typewriter 22

3.3 Ortholinear Keyboard Layout 24

4.1 A Printed Circuit Board (PCB) 28

4.2 A Home Automation PCB 28

4.3 Different Profiles of Keycaps 31

4.4 Components of a Mechanical Switch 32

4.5 Ideal Switch 33

4.6 Pressed Switch 33

4.7 Gateron Yellow (Linear Switch) 35

4.8 Akko V3 Pro Cream Blue (Tactile Switch) 36

4.9 Khail Box Jade (Clicky Switch) 37

4.10 Schematic Diagram 40

4.11 PCB Layout 41

4.12 Front Copper Layer Routing 42

4.13 Back Copper Layer Routing 42

4.14 Front Copper Layer Ground Planes 43

4.15 Back Copper Layer Ground Planes 43

4.16 Virtual 3D (Top View) 44

4.17 Virtual 3D (Bottom View) 44

4.18 Clearance & Spacing Check 45

4.19 Cygnus V1.0 47

4.20 Different Types of MX-Style Switches 48

4.21 Different Types of Low-Profile Switches 48

4.22 NRF52840 Pro Micro 49

4.23 JLC PCB’s Price Estimation 50

 Contents

Page No.

Acknowledgement i

List Of Figures iii

Chapter 1 Introduction 8

1.1 Introduction 8

1.2 Background 8

1.3 Purpose 9

1.4 Scope 10

Chapter 2 Ergonomic Keyboard Design 11

2.1 Ergonomics in Keyboard Design 11

2.2 Split Keyboard Concept 15

Chapter 3 Staggered vs. Ortholinear Layouts 20

3.1 Staggered Layout 20

3.2 Ortholinear Layout 23

3.3 Comparative Analysis 25

Chapter 4 Custom PCB Design in KiCad 27

4.1 Introduction to PCB Design 27

7
 4.2 Designing the PCB 29

4.3 Manufacturing Considerations 44

Last Chapter CONCLUSION 52

6.1 Summary of Findings 52

6.2 Future Work 54

Reference 55

8
 Chapter 1
Introduction

1.1 Introduction

In today's digital age, the keyboard is an essential tool for professionals, gamers, and
enthusiasts alike. With extended hours spent typing, the importance of ergonomics in keyboard
design has become increasingly prominent. Traditional keyboards, though widely used, often
lead to discomfort and long-term strain. This has spurred interest in ergonomic solutions,
particularly custom split keyboards. These devices offer a more natural hand positioning,
reducing the risk of repetitive strain injuries (RSI) and enhancing overall typing comfort.

This report delves into the design and development of a custom ergonomic split
keyboard, exploring the advantages of split layouts over conventional ones, and the superiority
of mechanical keyboards.

1.2 Background: Overview of Ergonomic Keyboards and the Need for

Customization

Ergonomic keyboards are designed to minimize the physical strain of typing. Traditional
keyboards, often with a staggered key layout, were originally developed to address mechanical
constraints rather than human comfort. Over time, however, it became clear that these designs
could lead to repetitive strain injuries, such as carpal tunnel syndrome, due to unnatural hand
positioning and prolonged use. This realization led to the development of ergonomic keyboards,
which prioritize the natural alignment of the wrists and fingers.

The QWERTY layout, the most common keyboard layout, was designed in the 19th
century for typewriters to reduce jamming by spacing out commonly used letter pairs. This
layout also introduced staggered keys, which were necessary due to the mechanical design of
typewriters. While the staggered design has persisted, it is not optimal for modern ergonomic
9
considerations, leading to the exploration of alternative layouts like ortholinear and split designs.

Split keyboards are a significant advancement in ergonomic design. By allowing users to

position the keyboard halves independently, they promote a more natural shoulder and arm
posture, reducing strain. Moreover, the ability to customize key layouts and switch to mechanical
key switches adds to their appeal. Mechanical keyboards, known for their durability, tactile
feedback, and precise actuation, have become the preferred choice for many users seeking a
high-quality typing experience. Customization in this context not only includes the physical
layout but also the design of the underlying Printed Circuit Board (PCB), which is crucial for
integrating the desired features and ensuring the keyboard's functionality.

1.3 Purpose

The primary objective of this project is to design and develop a custom ergonomic split
keyboard that combines the benefits of split layouts with the superior performance of mechanical
switches. This project aims to address the limitations of traditional keyboards by providing a
more comfortable typing experience, reducing the risk of strain injuries, and offering
customization options that cater to individual user preferences. The custom design will also allow
for exploration into the creation of a tailored PCB using KiCad, an open-source electronic design
automation software, ensuring that every aspect of the keyboard meets ergonomic and
performance standards.

10
1.4 Scope

This project will cover several critical aspects of custom ergonomic keyboard design:

 Layout Design: A comparative analysis of staggered versus ortholinear key layouts will
be conducted, focusing on ergonomics, typing efficiency, and user preferences. The split
keyboard design will be highlighted for its benefits in promoting natural hand
positioning and reducing strain.

 PCB Design: The process of designing a custom PCB using KiCad will be detailed.
This will include schematic creation, component selection, routing, and considerations
specific to split keyboards, such as connectivity and power distribution between the two
halves.

 Mechanical Key Switches: The report will also discuss the advantages of mechanical
keyboards over other types, emphasizing their durability, tactile feedback, and
customization options.

 Prototyping and Testing: The project will include the prototyping of the keyboard,
assembly, and rigorous testing to ensure that the final product meets the desired
ergonomic and performance standards.

11
 Chapter 2
Ergonomic Keyboard Design

2.1 Ergonomics in Keyboard Design

Introduction to Ergonomics in Keyboard Design Ergonomics is the study of designing tools and
environments that fit the user's physical needs, reducing strain and improving efficiency. When it comes
to keyboards, ergonomics focuses on optimizing the layout, key positioning, and overall design to align
with the natural movements of the human body. Poor ergonomic design can lead to discomfort, fatigue,
and long-term health issues such as carpal tunnel syndrome, tendinitis, and other musculoskeletal
disorders.

Key Factors Influencing Ergonomic Keyboard Design Several factors play a crucial role in the
ergonomic design of keyboards:

 Hand and Wrist Positioning

 Key Accessibility

 Wrist Support

 Angle and Tilt

 Split Layouts

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 2.1.1 Hand and Wrist Positioning

 Traditional flat keyboards force the wrists to bend upward as shown in Figure 2.1, a
position known as wrist extension. Over time, this can lead to strain on the tendons and
nerves in the wrists. Ergonomic keyboards aim to keep the wrists in a neutral position,
minimizing this strain.

Figure 2.1 A Traditional Flat Keyboard (HJ SNAKE AL75)

 The natural resting position of the hands, often referred to as the "home row," should be
maintained with minimal deviation. This means designing key layouts that require less
stretching and reaching.

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 2.1.2 Key Accessibility

Ergonomically designed keyboards ensure that frequently used keys are within easy reach of the
fingers, minimizing the need for excessive hand movement.

2.1.3 Wrist Support

Many ergonomic keyboards are designed to keep the wrists in a neutral position, often incorporating
wrist rests to support the hands at the correct angle, in Figure 2.1, Figure 2.2, Figure 2.3 & Figure 2.4 a
wrist rest is present below the keyboards.

Figure 2.2 A Wrist Rfiest

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 2.1.4 Typing Angle and Tilt

The angle and tilt of a keyboard can impact wrist positioning. Ergonomic keyboards often feature
adjustable tilt to help users find a comfortable angle that reduces wrist extension as shown in the
Figure 2.4.

Figure 2.3 An Ergonomic Keyboard (Akko ACR Pro Alice Plus)

2.1.5 Split Keyboard Design

The split design allows for the natural alignment of the hands, wrists, and shoulders, reducing ulnar
deviation (sideways bending of the wrist) and promoting a more comfortable typing posture.

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 2.2 Split Keyboard Concept

2.2.1 Introduction to Split Keyboards

Split keyboards are a specialized type of ergonomic keyboard designed to promote better posture,
minimize strain, and enhance typing comfort. Unlike traditional one-piece keyboards, split keyboards
are divided into two separate halves, allowing users to position each half independently for a more
natural hand and wrist alignment. This design addresses the discomfort associated with prolonged
typing on conventional keyboards, which can lead to issues like carpal tunnel syndrome, repetitive
strain injuries (RSI), and general muscle fatigue.

Ergonomic split keyboards have gained popularity among programmers, writers, and anyone who
spends significant time typing, as they offer customizable typing positions that accommodate different
body types and preferences. They are part of a larger trend toward personalized ergonomics, where
products are tailored to reduce stress on the body and improve long-term comfort.

The primary purpose of split keyboards is to improve user comfort and health. By allowing the user to
position each half of the keyboard according to their own shoulder width and arm angle, the design
reduces the unnatural inward twisting (ulnar deviation) that occurs when typing on a traditional
keyboard. With a split keyboard, users can keep their wrists in a more neutral position, which helps to
prevent strain and injuries over time.

Additionally, split keyboards can be configured for tenting, which raises the middle part of each half to
further reduce wrist pronation. The ability to separate the keyboard halves also means the user can angle
them to their preferred degree, which is particularly helpful for people with shoulder or back pain.

16
2.2.2 Benefits of Split Keyboards

 Natural Hand Positioning: Split keyboards allow users to position each half of the keyboard
shoulder-width apart, keeping the arms and wrists in a more natural alignment. This reduces
ulnar deviation and helps prevent strain on the wrists and forearms.

 Flexibility in Positioning: Users can adjust the angle and distance between the two halves of
the keyboard to find a position that suits their body and typing style. This customization
reduces the likelihood of developing musculoskeletal issues.

 Improved Posture: By allowing the arms to remain in a more relaxed and natural position,
split keyboards can promote better overall posture. This can reduce the risk of back, neck, and
shoulder pain that often results from prolonged typing on a conventional keyboard.

 Reduced Strain on the Shoulders: When using a traditional keyboard, the shoulders may be
internally rotated and strained. A split keyboard allows the shoulders to relax naturally,
reducing muscle tension.

 Customization for Typing Comfort: Some split keyboards also feature adjustable tenting
(where the keyboard halves are angled upwards) to further reduce wrist pronation and enhance
comfort.

17
2.2.3 Benefits of Split Keyboards

 Fixed Split Keyboards: These have a slight split in the middle but are still connected as one
unit as shown in the Figure. They offer some ergonomic benefits but lack the full flexibility of
completely separated halves.

Figure 2.4 A Fixed Split Keyboard (Record Alice)

 Adjustable Split Keyboards: These keyboards have two fully separate halves that can be
positioned independently. They offer the most customization and ergonomic benefits.

Figure 2.5 An Adjustable Split Keyboard (Lily58)

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  Tented Split Keyboards: Some split keyboards are designed with a tenting feature, where the
halves are angled upwards in the middle. This reduces wrist pronation and further enhances
comfort.

Figure 2.6 A Tented Split Keyboard (Corne Cherry)

2.2.4 Popular Examples of Some Prebuilt Split Keyboards

 ErgoDox EZ: A fully customizable, adjustable split keyboard known for its extensive
programmability and ergonomic design.

Figure 2.7 ErgoDox EZ

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  Kinesis Freestyle: Features an adjustable split design with tenting options, allowing users to
tailor the keyboard to their specific ergonomic needs.

Figure 2.8 Kinesis Freestyle

 Moonlander: A versatile split keyboard with tenting and adjustable thumb clusters, offering
a high degree of customization.

Figure 2.9 Moonlander

2.2.5 Challenges and Considerations

 Learning Curve: Switching to a split keyboard can involve a learning curve as users adapt to
the new layout and positioning.

 Portability: Split keyboards, especially those with separate halves, may be less portable than
traditional keyboards.

 Cost: High-quality split keyboards tend to be more expensive than standard keyboards due to
their specialized design and features.
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 Chapter 3
Staggered vs. Ortholinear Layouts

3.1 Staggered Layout

3.1.1 Definition and History of Staggered Layouts

 Definition: A staggered layout refers to a keyboard arrangement where the keys are offset from
one another horizontally, creating a stepped pattern. This design is primarily found in
traditional keyboards.

Figure 3.1 Staggered Keyboard Layout

 History: The staggered layout dates back to the invention of the typewriter in the late 19th
century. The original QWERTY layout, patented by Christopher Latham Sholes in 1868,
featured staggered keys. This design was necessary due to the mechanical limitations of early
typewriters, where each key was connected to a type bar that needed space to move. The
staggered arrangement allowed for the placement of keys closer together while preventing type
bars from jamming.

21
 Figure 3.2 A Typewriter

3.1.2 Advantages and Common Use Cases

 Advantages

1. Familiarity: The staggered layout is the most common design, and most users are
accustomed to it, which reduces the learning curve.

2. Widespread Adoption: Since most keyboards use a staggered layout, it's easier to find
replacements, parts, and accessories.

3. Compatibility: Most software and hardware are optimized for staggered layouts,
ensuring broad compatibility.

 Common Use Cases

1. Standard Keyboards: Almost all commercially available keyboards, from desktop to

laptop models, use a staggered layout.

2. Gaming Keyboards: Many gaming keyboards retain this layout for familiarity and ease
of use in fast-paced scenarios.

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3.1.3 Challenges and Limitations

 Hand Movement Inefficiency:

1. Misalignment with Natural Hand Positioning: The staggered layout does not align with the
natural position of the fingers, leading to awkward hand movements and increased strain,
especially during prolonged typing.

2. Inconsistent Key Spacing: The uneven spacing between keys can cause typists to make
more errors, particularly when transitioning between rows.

 Ergonomic Concerns:

1. Potential for Strain: The staggered layout can contribute to repetitive strain injuries (RSIs)
due to the unnatural finger movements required to reach certain keys.

2. Learning Curve for Alternative Layouts: Switching to an ergonomic or alternative layout

from a staggered one can be challenging due to the ingrained muscle memory of using a
staggered layout.

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3.2 Ortholinear Layout

3.2.1 Definition and Key Characteristics of Ortholinear Layouts

 Definition: An ortholinear layout features keys arranged in a straight grid pattern, where all
keys are aligned both vertically and horizontally. This layout is designed to match the natural
positioning of the fingers more closely.

Figure 3.3 Ortholinear Keyboard Layout

 Key Characteristics:

1. Straight Alignment: Keys are uniformly spaced in a grid, eliminating the horizontal
offset found in staggered layouts.

2. Symmetry: The grid pattern provides a symmetrical layout, which can help reduce the
cognitive load during typing.

3. Compact Design: Ortholinear layouts often allow for more compact keyboard designs, as
there is no need for the extra space required by staggered key rows.

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3.2.2 Comparison with Staggered Layout in Terms of Ergonomics and Typing
Efficiency

 Ergonomics:

1 Natural Finger Movement: The straight alignment of the keys in an ortholinear layout
better matches the natural movement of the fingers, potentially reducing strain and the
risk of repetitive strain injuries.

2 Reduced Finger Travel: With keys evenly spaced, typists may experience less finger
travel, leading to increased comfort during extended typing sessions.

 Typing Efficiency:

1 Increased Precision: The uniform key placement in ortholinear layouts can improve
typing accuracy by minimizing the need for lateral finger movement.

2 Learning Curve: Typists accustomed to staggered layouts may initially struggle with the
different spacing and alignment, but many users report increased speed and accuracy
after an adjustment period.

 Adoption in Modern Custom Keyboards:

1 Rise in Popularity: Ortholinear layouts have gained traction in the custom keyboard
community, particularly among enthusiasts looking for ergonomic improvements.

2 Examples: Keyboards like the Planck and Preonic have popularized the ortholinear
layout, offering compact and ergonomic designs that appeal to both typists and hobbyists

25
3.3 Comparative Analysis

3.3.1 Definition and Key Characteristics of Ortholinear Layouts

 Ortholinear Layout:

1 Pros: Offers a more natural alignment for fingers, potentially reducing strain and
improving comfort during long typing sessions.

2 Cons: Requires a period of adjustment for users familiar with staggered layouts; may not
be as universally comfortable depending on individual typing habits.

 Staggered Layout:

1 Pros: Familiar to most users, which can reduce the immediate discomfort of switching to
a new layout.

2 Cons: Less ergonomic, with a higher risk of strain due to the unnatural key alignment.

3.3.2 User Preference Trends

 Traditional Users: Many users continue to prefer staggered layouts due to familiarity and the
ease of use with existing hardware and software.

 Ergonomic Enthusiasts: Users who prioritize ergonomics and comfort are more likely to adopt
ortholinear layouts, often reporting increased satisfaction after adapting.

 Enthusiast Communities: The custom keyboard community shows a growing trend toward
ortholinear and other alternative layouts, driven by a desire for personalized ergonomics.

26
3.3.3 Performance Metrics
 Typing Speed:

1 Ortholinear Layout: Some users report a slight decrease in typing speed initially due to
the learning curve, but this often improves with practice, potentially surpassing speeds on
staggered layouts.

2 Staggered Layout: Typically allows for faster typing speeds initially due to widespread
familiarity, but may plateau due to ergonomic inefficiencies.
 Error Rates:
1 Ortholinear Layout: Users may experience lower error rates once accustomed to the
layout, as the uniform grid can reduce the chance of miskeying.

2 Staggered Layout: Higher error rates may occur due to the uneven key spacing and the
need for more precise finger movements across rows.

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 Chapter 4
Custom PCB Design in
KiCad
4.1 Introduction to PCB Design
 Basics of PCBs and Their Role in Keyboard Design

1. Printed Circuit Boards (PCBs) are the backbone of modern electronic devices, serving as
the platform on which all electronic components are mounted and interconnected. They
provide mechanical support and electrical connections between components using
conductive pathways, tracks, or signal traces etched from copper sheets laminated onto a
non-conductive substrate.

Figure 4.1 A Printed Circuit Board (PCB)

28
 Figure 4.2 A Home Automation PCB

2. In keyboard design, the PCB is crucial as it connects key switches to the microcontroller,
which registers keypresses. The layout of the PCB must align with the physical design of
the keyboard, ensuring each key is correctly placed and connected. For split keyboards,
PCBs must accommodate the physical separation of the keyboard halves while
maintaining connectivity and power distribution.

 Overview of the KiCad Tool

1. KiCad is a free, open-source software suite for Electronic Design Automation (EDA). It
allows users to create schematics, design PCB layouts, and prepare them for
manufacturing.

2. KiCad offers a range of tools for creating complex PCB designs, including a schematic
editor, PCB layout editor, and tools for generating bills of materials (BOM) and Gerber
files (the standard format for PCB manufacturing).

3. Key Features:

I. Schematic Capture: Allows designers to draw the circuit, select components, and
define electrical connections.

II. PCB Layout: Provides tools for placing components on the board and routing the
connections between them.

III. 3D Viewer: Visualizes the PCB in 3D, helping designers to inspect the board and
ensure it meets design requirements.

IV. Gerber Generation: Outputs files in the format required for manufacturing.

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 4.2 Designing the PCB

4.2.1 How Does a Mechanical Keyboard Work?

Before Designing the Custom PCB for our Split Keyboard, we should know how a Mechanical
Keyboard works:

Mechanical keyboards have become the preferred choice among enthusiasts, gamers, and professionals
due to their durability, customizability, and superior typing experience.

1. Overview of Mechanical Keyboards

A mechanical keyboard operates by using individual mechanical switches under each key,
rather than a membrane or rubber dome typically found in standard keyboards. Each switch is
a complex system that determines how the keyboard registers a keypress.

2. Key Components of a Mechanical Keyboard

 Keycaps

 Mechanical Switchs

 PCB (Printed Circuit Board)

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 Keycaps:

1. The keycap is the top part of the key that you press. It is removable and comes in various
shapes, sizes, and materials like ABS, PBT, Metal, Ceramic, etc.

2. Customization: Users can switch keycaps to enhance the aesthetic or functional

experience (e.g., different textures or profiles for different keys).

Figure 4.3 Different Profiles of Keycaps

 Mechanical Switch:

1. The heart of the mechanical keyboard is its switch, which consists of several small
components that work together to register keypresses. There are many types of switches,
each offering different feel and performance characteristics.

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2. Components of a Mechanical Switch:

a. Housing: The outer shell that holds the internal components together.

b. Stem: The central piece that moves downward when the key is pressed. The design of
the stem dictates the feel of the switch (e.g., linear, tactile, clicky).

c. Spring: Provides the resistance felt when pressing the key. The strength of the spring
affects how hard the key is to press and how it rebounds.

d. Contacts: Metal contacts within the switch that touch when the key is pressed,
completing the circuit and sending the signal to the computer.

Figure 4.4 Components of a Mechanical Switch

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 PCB (Printed Circuit Board):

1. The mechanical switches are mounted onto the PCB, which registers the electrical signals
from the switch and sends them to the computer.

2. The PCB is responsible for interpreting each keypress and sending the corresponding data
via a USB connection to the computer.

3. Working Mechanism

 Key Press Detection:

1. When a key is pressed, the switch stem is pushed down, compressing the spring inside the
switch.

Figure 4.5 Ideal Switch Figure 4.6 Pressed Switch

2. For tactile switches, a "bump" is felt as the stem moves past a certain point, providing
feedback to the user that the keypress has been registered. For clicky switches, this
feedback is also accompanied by an audible "click" sound.
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 Electrical Signal Registration:

1. As the stem reaches a certain point, the metal contacts inside the switch meet, completing
the circuit.

2. Once the circuit is closed, a signal is sent to the keyboard's controller, which interprets the
specific key that was pressed.

 Signal Transmission to Computer:

1. The controller sends this information through the PCB and then to the computer via USB
or Bluetooth (depending on the keyboard’s connection type).

2. The computer's operating system receives the input and performs the corresponding
action (e.g., displaying a character, performing a command).

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 4. Types of Mechanical Switches

Mechanical switches come in various types, each with different characteristics that affect typing feel
and sound:

 Linear Switches:

1. These switches provide smooth keystrokes from top to bottom with no tactile feedback or
audible click.
2. Popular with gamers for fast keypresses due to the lack of resistance.
3. Examples: Cherry MX Red, Gateron Yellow.

Figure 4.7 Gateron Yellow (Linear Switch)

35
 Tactile Switches:

1. Tactile switches have a noticeable bump halfway through the key press, providing
physical feedback when the keypress is registered.

2. Favored by typists for the feedback, allowing for precise and accurate typing.

3. Examples: Cherry MX Brown, Zealios, Akko V3 Pro Cream Blue.

Figure 4.8 Akko V3 Pro Cream Blue (Tactile Switch)

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 Clicky Switches:

1. Similar to tactile switches but also feature an audible click sound at the point of actuation.

2. Favored by typists for the feedback, allowing for precise and accurate typing Preferred by
users who enjoy auditory feedback or want confirmation that a key has been pressed.

3. Examples: Cherry MX Blue, Razer Green, Khail Box Jades.

Figure 4.9 Khail Box Jade (Clicky Switch)

5. Advantages of Mechanical Keyboards

 Durability:
Mechanical switches are rated for tens of millions of keystrokes, making mechanical keyboards
much more durable than membrane keyboards.
37
 Customization:

1. Users can customize the switches, keycaps, and even the layout of their keyboards.

2. Hot-swappable PCBs allow for switches to be easily changed without soldering.

 Typing Experience:

1. Mechanical keyboards provide a more consistent and satisfying typing experience due to the
individual switches.

2. The variety of switches allows users to choose their preferred typing feel, whether it’s smooth,
tactile, or clicky.

6. Disadvantages of Mechanical Keyboards

 Cost:
Mechanical keyboards tend to be more expensive due to the higher quality components and
durability of mechanical switches..

 Noise:
Depending on the switch type, mechanical keyboards can be noisy, particularly with clicky switches .

 Weight and Size:

Mechanical keyboards are typically heavier and bulkier than membrane keyboards, which can be a
downside for portability.

4.2.2 Steps in Designing a Keyboard PCB on KiCad

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  Schematic Creation: Selecting and Placing Components

1 The first step in designing a PCB is creating the schematic, which is a visual representation of
the electrical circuit.

2 Component Selection: Choose the necessary components, including microcontrollers, diodes,

resistors, capacitors, and connectors. For keyboards, mechanical switches and LEDs (if
backlighting is desired) are key components.

3 For our keyboard build we have selected the following components:

Sr. No. Component Quantity

1
PCB 2

2
SuperMini nRF52840 Pro Micro MCU 2

3
SMD Reset Button 2

4 Li-Po Battery(450mAh) 2

5 MX Style Switches 34

6 MX Style Keycaps 34

7 Male Headers 2

8 Female Headers 2

9 MSK12C02 SMD SPDT Switches 2

Table 4.1 Components List

39
 4 Schematic Capture: Place the selected components in the schematic editor and connect them
using virtual wires to represent the electrical connections.

Figure 4.10 Schematic Diagram

Here’s a Video of me Building the 1st Iteration of the Keyboard

40
4.2.3 Routing: Optimizing Paths for Signals
 PCB Layout: Once the schematic is complete, we import it into the PCB layout editor. Here, we
arrange the physical positions of components on the board.

Figure 4.11 PCB Layout

 Signal Routing: Draw the traces (paths for electrical signals) that connect components according

41
 to the schematic.

Figure 4.12 Front Copper Layer Routing

Figure 4.13 Back Copper Layer Routing

 Ground Planes: Using large copper areas connected to the ground to reduce electromagnetic
42
interference (EMI) and provide a stable reference voltage.

Figure 4.14 Front Copper Layer Ground Planes

Figure 4.15 Back Copper Layer Ground Planes

43
 Figure 4.16 Virtual 3D (Top View)

Figure 4.17 Virtual 3D (Bottom View)

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 4.3 Manufacturing Considerations

4.3.1 Preparing the Design for Manufacturing

Manufacturing a custom ergonomic split keyboard involves ensuring that your PCB design is
optimized for both functionality and ease of production. Key steps include:

 Design for Manufacturability (DFM):

1 Clearance and Spacing: Ensure that the copper traces, vias, and pads have appropriate
spacing to avoid short circuits during manufacturing. This spacing should meet the tolerance
standards of the manufacturer.

Figure 4.18 Clearance & Spacing Check

2 Component Placement: Components should be positioned logically to avoid tight spaces

that could be difficult to solder, either manually or with a machine. Ensure there is enough
room for connectors, microcontrollers, and key switches.

3 Solder Mask and Silkscreen: Add solder mask layers to prevent short circuits between
traces. The silkscreen layer should clearly mark component placement and orientation to aid
45
 in assembly.

4 Panelization: If you are producing multiple units, consider panelizing the PCB, which means
arranging multiple copies of the design onto a single sheet. This improves manufacturing
efficiency.

5 Test Points: Include test points on the PCB for checking continuity and verifying that signals
are flowing properly during production.
 Bill of Materials (BOM):

A comprehensive BOM should be generated from the PCB design. It should include all
components such as microcontrollers, key switches, resistors, diodes, and capacitors. The BOM
should also list the manufacturer part numbers to ensure accurate sourcing.

 Gerber Files:

The Gerber files, which are the industry standard for PCB production, must be correctly
exported from KiCad. These files include information about each PCB layer, including the
copper layers, solder mask, and silkscreen. Double-check the files to ensure alignment and
avoid any issues in production.

4.3.2 Choosing the Right Materials and Components

Selecting the appropriate materials and components is critical for ensuring the durability, functionality,
and cost-effectiveness of your custom keyboard. Consider the following:

 PCB Material:

1. FR-4: The most commonly used material for PCBs is FR-4, a composite material made from
woven fiberglass and epoxy resin. It is affordable, durable, and suitable for most keyboard
designs.

2. Flexible PCBs: If you need a more adaptable design or aim for a slimmer profile, flexible

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 PCBs made from polyimide may be considered. However, they are more expensive and
complex to manufacture. Using these PCBs we can manufacture something like the Cygnus.

Figure 4.19 Cygnus V1.0

 Copper Thickness:

Standard copper thickness is typically 1 oz/ft², which is sufficient for keyboard circuits. If you
plan on having additional features that require more power, such as RGB lighting, consider
using thicker copper.

 Key Switches:

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 1. Mechanical Switches: Cherry MX-style switches or clones are a common choice for custom
keyboards. Consider the actuation force, durability (measured in keystrokes), and sound
profile (clicky, linear, or tactile).

Figure 4.20 Different Types of MX-Style Switches

2. Low-profile Switches: For slimmer designs, low-profile switches like the Kailh Choc or
similar may be more appropriate, though they might limit the availability of keycaps .

Figure 4.21 Different Types of Low-Profile Switches

 Microcontrollers:
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 The microcontroller unit (MCU) will be the brain of your keyboard. Common choices include
the Atmel ATmega32U4 (used in popular designs like the Pro Micro) or more advanced ARM-
based MCUs like NRF52840 Pro Micro depending on the performance requirements.

Figure 4.22 NRF52840 Pro Micro

 Connectors and Cables:

TRRS connectors (for connecting split halves) or USB-C connectors (for power and
communication) should be chosen based on the design’s needs. USB-C offers a modern,
reversible connection with fast data transfer.

4.3.3 Cost Estimation and Optimization

Careful cost estimation and optimization are essential to make your keyboard both affordable and
scalable, especially if you plan to produce multiple units.

 Component Sourcing:

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 1. Bulk Purchasing: Buy key components like switches, diodes, and microcontrollers in bulk to
reduce the cost per unit.

2. Supplier Comparison: Compare prices from various suppliers, especially for more expensive
components such as microcontrollers and PCBs. Check platforms like DigiKey, Mouser,
Quarts Components, LCSC, or Robu for pricing.
3. Shipping Costs: Factor in international shipping costs, especially for custom PCB
manufacturing and component sourcing from overseas (JLC PCB).

 PCB Manufacturing Cost:

1. Manufacturer Selection: The cost of PCB manufacturing can vary greatly depending on the
manufacturer and order quantity. Popular choices include JLCPCB, PCBWay, and Robu.
Each offers competitive rates, but smaller quantities are often more expensive per unit.

Figure 4.23 JLC PCB’s Price Estimation

2. Size and Layers: The size of the PCB and the number of layers influence cost. Standard
PCBs are two-layer, but if your design is complex, a four-layer PCB may be necessary,
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 though more expensive.

3. Surface Finish: A common and affordable surface finish is HASL (Hot Air Solder Leveling).
For better durability, especially with gold-plated connectors, ENIG (Electroless Nickel
Immersion Gold) is a more expensive option.

 Assembly Cost:

1. Automated vs. Manual Assembly: Hand soldering is viable for small batches but time-
consuming. Automated assembly is more efficient for larger production runs but increases the
cost upfront.

2. Outsourcing Assembly: If you're not assembling the PCBs yourself, outsourcing assembly to
companies that offer turnkey solutions (such as PCB manufacturing and assembly) can
streamline the process.

 Prototyping and Iteration:

1. Initial Prototypes: Allocate a portion of the budget for prototype manufacturing. Testing
prototypes thoroughly will help you avoid costly mistakes during mass production/Group
Buys.

2. Minimizing Rework Costs: Ensure that the design is thoroughly tested and reviewed before
sending it for production. Catching errors in the design stage can save significant costs down
the line.

 Overall Cost Optimization:

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1. Minimizing Waste: Optimize the PCB design to reduce waste in the manufacturing process,
such as minimizing the PCB footprint or reducing the number of layers if possible.

2. Material Trade-offs: Choose materials that balance cost and durability based on the use case.
For example, if the keyboard is intended for general use, expensive materials like polyimide
may not be necessary.

3. Scaling Production: If the project goes beyond personal use (e.g., a group buy), scaling up
production can reduce per-unit costs due to economies of scale.

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 Chapter 5
Conclusion
5.1 Summary of Findings

In this project, the development of a custom ergonomic split keyboard involved a thorough exploration
of two key elements: keyboard layout and PCB design. The main findings from the research and design
process include:

 Ergonomics and Comfort: Split keyboards provide significant ergonomic benefits by allowing
users to position the two halves of the keyboard at shoulder-width distance, reducing strain on
wrists, arms, and shoulders. This flexibility offers personalized comfort, which is one of the major
reasons they outperform traditional keyboards in terms of ergonomics.
 Staggered vs. Ortholinear Layouts:

1. Staggered Layout: While the staggered layout remains popular due to its historical
prevalence (as seen in QWERTY keyboards), it has limitations when it comes to hand and
finger efficiency. The staggered design, originally created to accommodate typewriters,
forces extra hand movement, which can lead to strain over extended periods.

2. Ortholinear Layout: The ortholinear layout offers a more uniform and efficient key
arrangement, reducing unnecessary hand movement. This results in improved typing speed
and reduced fatigue over time. Although ortholinear layouts require a learning curve for users
accustomed to staggered designs, they are generally considered better suited for ergonomic
applications.

 Custom PCB Design:

The custom PCB design using KiCad allowed for a tailored layout and component arrangement.
Key insights from the PCB design process include:
1. Designing for split keyboards involves ensuring proper communication between the two
halves, often achieved using I²C or UART protocols.

2. Optimizing the PCB layout to maintain efficient routing while keeping the overall size
compact is essential, especially for split designs.
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 3. Managing power distribution and grounding effectively across both halves of the keyboard is
crucial to avoid electrical noise and ensure proper functioning.

4. Proper documentation and design for manufacturability are essential to streamline the
production process.

Overall, the project demonstrated the advantages of customizing keyboards to enhance user comfort
and typing efficiency. Custom PCB design offered significant flexibility, enabling precise control
over layout and functionality.

5.2 Future Work

Though the project successfully delivered a functional custom ergonomic split keyboard, there are
several areas where improvements and further research could be valuable:

 Layout Customization: Future versions could explore additional ergonomic layouts beyond
staggered and ortholinear designs, such as columnar-staggered or curved layouts, which align
more closely with the natural movement of fingers and hands.

 Firmware Optimization: The integration of advanced firmware, such as QMK or ZMK, could
provide better control over key mapping, layers, and macros. Future iterations could focus on
optimizing firmware for ease of use, allowing users to make customizations without needing
programming experience.

 Wireless Connectivity: Moving to a wireless design would enhance the portability and
convenience of the split keyboard. Research into low-power wireless communication methods like
Bluetooth Low Energy (BLE) could be pursued to develop a battery-efficient solution.

 Improved Materials and Components: The use of higher-quality materials for key switches, such
as hot-swappable mechanical switches, could improve the overall user experience and keyboard
durability. Additionally, exploring new materials for the case and keycaps, such as 3D-printed
enclosures or more eco-friendly materials, could be a direction for future work.

 User-Centered Design Iterations: Conducting further user testing and gathering feedback from a

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 wider range of users would allow for iterative design improvements. This can help refine the
ergonomics, key placement, and overall usability of the keyboard.

 Haptic Feedback and Force Sensing: Integrating haptic feedback and force-sensitive resistors
(FSRs) into future designs could provide real-time feedback on typing pressure, potentially
reducing strain further by helping users adjust their typing force dynamically.

 Exploration of Alternative Power Sources: Investigating energy-efficient solutions, such as solar-

powered keyboards or energy harvesting from key presses, could lead to innovations in powering
split keyboards without the need for frequent charging or battery replacement.

In conclusion, the development of custom ergonomic split keyboards offers a promising direction for
improving user comfort and typing efficiency. With advancements in layout design, firmware, and
materials, future iterations have the potential to significantly enhance the user experience in both
professional and personal settings. Further research could also push the boundaries of keyboard
customization, allowing for even greater personalization and ergonomic benefits.

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 Reference

1 https://github.com/Aposymbiont/split-keyboards

2 https://github.com/diimdeep/awesome-split-keyboards

3 https://github.com/joe-scotto/scottokeebs/tree/main

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