1/8/2026 8 PM - Created a proof of concept and layout design!

I quickly created a layout / design in affinity designer. My plan is to include exactly 60 keys, arranged in the layout shown. The keyboard will be wireless and battery powered by running on the XIAO nrf52840 with wireless capabilities and built in power management.

Next, I will begin the schematic. This is my third attempt at this project (istg), so I think I know what to look out for this time to avoid large cost increased in materials, as the XIAO chips are quite expensive.

1/8/2026 9 PM - Left and Right Schematic Completed

I created the left and right schematics (which are the same) using a keyboard matrix. I learned how to do this already from the hackpad project, and it was fun to try and apply my skills to a larger matrix. I also added footprints for the battery contact points and mounting holes, and wired everything to the main board.

I ended up having to use every GPIO port for the matrix, so I will not be able to add a voltage sensor for the batteries. I also used linked sheets so that I did not need to route everything twice over, and added some breakoff footprints where the keyboard will split in two. Next, I will route the PCB fully and create the board!

1/9/2026 6 PM - PCB Created & Routed!

First, I exported a "stencil" from affinity designer (as I don't think KICAD's positioning system is great) and used that along with the courtyard markers to align my switches. Then, I aligned the XIAOs and test points in an accessible place.

Creating the PCB outline was actually quite difficult, and it took me many attempts to create something I liked. The outline was created using just the line tool, and then I filleted the corners to make it slightly more premium looking. I added mounting points where they fit, routed all of the switch matrix with the diodes, and my PCB (aside from some silkscreen designs) is complete!

Next, I will create the 3D printed case in fusion, and try to find some cheap parts on Ali!

1/9/2026 7 PM - Custom silkscreen!

I created a custom silkscreen for my PCB. The back pattern is somewhat of an experiment, but it won't visible anyway so I thought I would try something crazy. The pattern is from https://pattern.monster/, and I created the front designs myself (including my logo), and cleaned up unnecessary labels.

1/9/2026 11 PM - Created base of case

I spent a while creating the base in fusion. First, I figured out how to import my PCB and components to help make the design process easier. This was my first time using the arc tool in sketches, and I think that it really increased the premium feel. I have definitely improved my fusion skills since the hackpad, and I am excited to print my design with the new filament I received from Blueprint!

I also created a small cutout for the USB-C port on the XIAO, and I am leaving space below the PCB for the batteries. The small circles are risers, and all holes will be fitted with threaded inserts. Next, I will create a top for this case, and get ready to ship my project!

1/10/2026 1 PM - CAD Lid

I created the lid of my enclosure using my existing sketches in fusion. I traced the edge of the PCB to make sure the switches will line up. I used the same USB cutout style as the base, and made everything match up. The lid will be attached using six M3 screws into threaded inserts in the base. I also created a little bit to cover the XIAO when the lid is on.

I also created a full assembly STEP file.

1/10/2026 3 PM - 3D Renders

I created two renders of the assembled project in blender. I imported all of the parts as STL's from fusion and created some basic studio lights and background. I rendered one with and one without keycaps, and I think they turned out really neat! The de noising looks pretty bad, but I can't use more samples in cycles.

1/18/2026 - CAD Measurements Redesign and Print

I changed some case measurements so that the keys will actually align correctly, and increased the overall height so that the battery will (hopefully) fit under the pcb. I also had to redesign the USB port hole for the top of the case and reprint as I realized it would not be nearly big enough, and I changed the hole diameter to match the screws and threaded inserts I bought from AliExpress

Lastly, after hours of troubleshooting, I was able to get clean prints for the left half. I am waiting to print the right side until I receive parts and I know the dimensions are correct. Just hoping PCB arrives before the 31st.

I am very excited to begin building!

1/24/2026 - Final Layout Decisions

While I'm waiting for my PCBs to arrive, I decided to make some layout decisions. I will use the additional square keys provided for all of the keys other than numbers and letters. I laid out all of the keycaps and found a layout that works well with my design. I am using the slightly rectangular keys for space, ctrl, and alt keys. I also mounted the threaded inserts into my case.

1/27/2026 - Soldered the diodes, messed up the MCU

First, I did a test fit with all of the switches to make sure my case dimensions were correct. Everything seems to be good!

I then soldered on all of the diodes. This was a painful process, and soldering SMD components by hand is not fun at all. I had to hold the diode with pliers in one hand while heating the pads with my other, after I had already put solder on the pad.

I then (attempted) to solder my XIAO clone on. I was so happy with it until I looked and realized I had soldered it on upside down! I am genuinely so pissed right now, and I ordered the hot plate and solder wick from the shop to attempt to remedy this. For now, I am taking a break from this project.

2/7/2026 - Resoldered XIAO, soldered key switches, assembled

My hot plate and solder wick finally arrived! I immediately started up the hot plate (after testing five different power supplies) and removed my previous mistake solder job of the devboard. I resoldered it on the correct direction this time, but I may have made some other mistakes.

I soldered on all of the key switches as well, which was so nice compared to the previous smd soldering. I assembled my whole keyboard to see how it looks, and I am so happy.

I used some arduino test code (from chatgpt) as I could not get CircuitPython to work, and I tested my key matrix. Unfortunately, it does not work very well. I believe that two sets of two pads on the XIAO are connected together, and I will have to remove the XIAO again to fix this.

2/11/2026 - Designed and Printed Right Side, resoldered chip again

First, I removed and resoldered the chip for a final time on the left side! I used the hot plate again for removal, and this time I attached it by putting solder on all of the PCB pads (while hot from hot plate) and slowly lowering the devboard on it. I used AI to write a test script and the matrix works completely!

I also redesigned the CAD somewhat for the right side, as the holes in the PCB were not lined up correctly with the standoffs on the base, and 3D printed the right half! I did a mock assembly for the right side for a photo. They look so cool!