Keyboard plate design,step by step.

A plate holds switches in position. Its openings and supports must match the PCB (circuit board) and case. Follow this TOFU65 3.0 example through seven stages.

1. 01

   KLE / KEY POSITIONS

   Set the layout.

   Keyboard Layout Editor (KLE) sets key positions and widths. Edit Default 60% into this 67-key layout, then copy the Raw data tab.

   Key widths use u: 1u = 19.05 mm key spacing, not the size of a switch opening.

   

   KLE settings for this example

   X/Y locate a key’s upper-left corner in u: X right, Y down.

   • Label the first key Esc and the spacebar Space.
   • Right Shift: X 12.25, Y 3, Width 1.75.
   • At Y = 4, delete Menu (X 12.5) and Ctrl (X 13.75). Keep Alt at X 10; rename Win at X 11.25 to Fn.
   • Add these eight 1u × 1u keys.

   Additional keys · X / Y in u

   Key	X	Y
   Delete	15	0
   PgUp	15	1
   PgDn	15	2
   Up	14	3
   End	15	3
   Left	13	4
   Down	14	4
   Right	15	4

   Where to copy Raw data

   

2. 02

   AI03 / STARTER GEOMETRY

   Generate the base cutouts.

   ai03 converts the layout into switch and stabilizer openings. Download its DXF, then import it into an XY sketch in millimeters in Autodesk Fusion (CAD software).

   

   Remove the imported outer rectangle and name the sketch Base holes. Check one switch opening: 14 × 14 mm.

   Generator and import settings

   • Paste Raw data into KLE Data. Add _rs:180 beside Space’s w:6.25 to rotate its stabilizer openings. Add it here; KLE discards it.
   • Both cutout types: Cherry MX Basic; fillets 0.5 mm; Acoustic Cutout None; unit width/height 19.05 mm; kerf 0.
   • Save as base-layout.dxf. In Fusion: Insert DXF → Origin → XY; Millimeter, Single Sketch, X/Y = 0. Delete only the four layout-rectangle lines.
3. 03

   FUSION / KEY COMPATIBILITY

   Add the layouts you need.

   Only add positions supported by your PCB. The split-Shift example shows how one opening can support several layouts.

   Copy distances below start from the original switch center.

   Key units and coordinates

   

   Work on a copy. Copy all Base holes curves into a new Origin → XY sketch without moving or rotating them. Name it Final holes; hide Base holes.

   Fusion basics: select, copy and trim

   

   Case study: split Left ShiftOne key or two keys in the same area

   2.25u becomes 1.25u + 1u. Both layouts share the left edge. Different key widths place the new switch centers at unequal offsets.

   

   LEFT COPY · X DISTANCE-19.05/2−0.5u · −9.525 mm

   RIGHT COPY · X DISTANCE19.05*0.625+0.625u · approximately +11.91 mm

   • Select the original switch cutout’s four edges + four arcs. Use M → Sketch Objects → Translate → Create Copy with the X values above and Y = 0.
   • Confirm OK → Esc, then reselect the original for the second copy. Keep the original cutout and stabilizer openings.
   • Trim an edge only when both sides belong to the opening. Keep the outer boundary and switch clip-contact edges.

   Check: all three switch positions fit the intended layout; the cut areas are closed profiles and the stabilizers remain clear.

   BackspaceEqual halves use equal offsets

   2u becomes 1u + 1u. Copy the original switch opening −9.525 mm and +9.525 mm in X. Keep Y unchanged, then trim internal overlaps.

   

   For the illustrated v1 shape, add a 7 × 4 mm lower relief at each original stabilizer opening, with R0.5 inside corners. Keep the center position and switch holding edges.

   Caps LockA second position within the same key area

   For this stepped-Caps option, copy the original opening 0.25u left: X = -19.05/4, Y = 0. Trim the internal overlaps into one closed boundary.

   

   ANSI / ISO EnterRegenerate the complete two-row arrangement

   ISO changes both Enter and the key above it, including the stabilizer orientation. Generate the complete option before combining it with ANSI.

   

   KLE values and import steps

   Change these two keys in Properties

   Select the old key	X / Y	Width / Height	New label
   Backslash	13.75 / 1	1.25 / 2	ISO Enter
   ANSI Enter	12.75 / 2	1 / 1	ISO extra

   In a copy of the base layout, change these two keys and keep all others fixed. Use primary Width = 1.25, Height = 2 for the ISO Enter preview.

   Generate iso-option.dxf with Step 02 settings, including Space’s _rs:180. Import it into a separate XY sketch at X/Y = 0; unchanged keys must coincide. Copy the changed curves into Final holes, remove duplicates and trim overlaps.

   Check: retain both Enter centers, neighboring key openings and both stabilizer orientations. Remove the shown inner square’s four edges so no detached material island remains.

   6.25u / 7u SpacebarReposition the switch and both stabilizers

   Regenerate the full bottom row: changing Space moves the switch and stabilizers, and can change neighboring modifier positions.

   

   KLE values and import steps

   Build this example 7u bottom row in Properties

   Key	X	Width
   Left Ctrl	0	1.5
   Win	1.5	1
   Left Alt	2.5	1.5
   Space	4	7
   Fn	11	1.5

   Keep Y = 4, Height = 1. Delete Right Alt; keep arrows at X = 13, 14, 15 for eight keys total. Generate 7u-option.dxf with Step 02 settings and _rs:180 beside Space’s w:7.

   Import into a separate XY sketch at X/Y = 0. Copy changed curves into Final holes; trim overlaps.

   Check: these two Spacebar sets form four separate closed regions. Do not connect holes that do not overlap. Check the neighboring modifier positions too.

   TOFU65 layout and plate reference

   

   

4. 04

   FUSION / CASE FIT

   Draw the outline and supports.

   The generator supplies holes, not the finished case interface. Create a separate Plate outline sketch at the same XY origin, using the matching case dimensions.

   

   Build one tab, then copy it to the eight positions. Mirror the lower tab shape before positioning it; upper and lower centers do not all align.

   TOFU65 dimensions and outline checks

   

   Keep locating lines as Construction. Join boundary endpoints with Coincident constraints; remove duplicate lines. The plate region should shade, with each tab connected and each C-slot a separate opening.

5. 05

   OPTIONAL / FLEX SLOTS

   Decide whether to add flex slots.

   Flex slots change how the plate bends. Their effect also depends on the material, remaining bridges and supports. Confirm minimum slot and bridge sizes with your fabricator for the material, thickness and process.

   See a flex-slot experiment

   

   1 mm is this exercise’s finished slot width, not a universal specification or laser kerf. In a test copy, create Flex test on XY. Draw a Center To Center Slot from (40, −19.05) to (100, −19.05) mm. After Step 06, cut it as a separate feature; suppress it to compare. Keep holding edges intact and check PCB/case clearance.

6. 06

   FUSION / FROM 2D TO 3D

   Build and cut the plate.

   Match thickness to the intended switch and case; this example uses 1.5 mm.

   • Extrude Plate outline, excluding C-slots: New Body, −1.5 mm.
   • Select the finished Final holes profiles from Step 03: Extrude → Cut → All, directed into the body.

   

   Check for one connected body, open cutouts and intact mounting features. Add any local underside details required by the case.

7. 07

   EXPORT / CHECK THE FILES

   Export STEP and DXF.

   STEP / 3D BODY

   Save the solid.

   File → Export → STEP. Reopen it and check one solid in millimeters.

   DXF / FLAT CONTOURS

   Save the cutting profile.

   In a new XY sketch, Project the entire top face. Finish, then Save As DXF. Reopen and check the outline and all holes at 1:1 in mm.

   Keep the editable Fusion file. Use STEP for depth details; test a small sample before making the full plate.