FWIW, during a build a couple of days ago I tried using strips of 0.188" thick Sorbothane between the plate and PCB, and found this to still be too much contact; it felt like too much pressure to bring the switch bottoms into contact with the PCB. I ended up thinning some of the strips with scissors to reduce the thickness by about a third, which, as you might imagine, was not exactly a precise operation. But it was close enough to get meaningful sound dampening. This experience got me wondering what the ‘ideal’ thickness might be for this application.
Working from the Cherry MX specs, there should be at most 3.5mm (0.138") of clearance between the bottom of a 1.5mm plate and the PCB. There are 0.125" sheets that appear on Amazon, but I’m not sure that’s quite thick enough to make good contact, and while I don’t have a good set of calipers, a quick straightedge measurement also suggests 0.125" isn’t quite enough.
Going deeper into the rabbit hole, this engineering guide suggests that a deflection of 10-20% is good for dampening with shape factors between 0.3-1.0. The shape factor is the ratio of loaded (dampened) surface area to unloaded surface area. As an approximation to the total surface area of a 60% plate, the dimensions of a GH60 PCB are 285mm x 94.6mm, which gives us a surface area of 41.8 sq in. As an approximation to unloaded surface area, we can use the combined footprint of 65 switches, which is 0.61" x 0.61" x 65 = 24.2 sq in. Loaded = total - unloaded = 41.8 - 24.2 = 17.6. This yields a shape factor of 17.6 / 24.2 = 0.72. So, 10-20% deflection on a thickness of 0.138" suggests we want the Sorbothane filling for our plate/PCB sandwich to be somewhere in the 0.151"-0.166" range.
All of which is to say - at the moment, I’m less excited than I originally was about 0.18" precut plate/PCB sheets, but more excited about something like 0.155", assuming sheets of that thickness are feasible from both manufacturing and pricing perspectives.
Great write up, I’ve been speaking to the manu. about my plans for the future rounds and are still working back and forth about my plans with them.
What a lot of it comes down to is the pricing to be honest. I already know the quote to have the appropriate thickness of precut sheets, and it’s over $100 per sheet if you want it to be cut out per switch. I don’t think that’s a worthwhile value for anyone in the community to be perfectly honest.
I’m trying to work with them on an ‘effective enough, but affordable enough’ solution with them, and right now what I’m working on is overcoming the failure rates for the thickness/size/cutting. Obviously I don’t think a single person here should spend over $100 for a sheet precut for a 60% (Sorbathane plates anyone?), but I’m working on it.
I’ll take what you said in mind (I have maths of my own to work out), and hopefully for R2 I can have some exciting exclusive products to share with you all
For right now, I’m just working on making sure R1 production and shipping goes smoothly hehe.
Yup, totally get it - arguably I should have written this up in a different thread, but I remembered the subject of thickness coming up here, and I got excited. Ha!
Back to your regularly scheduled program. Thanks again for the push on R1!
Not sure what was the price but are you planning offering any sorbothane sheet with custom cut?
I like sorbothane between plate and pcb (where i think it works the best, compressed as hell), while in the case it doesn’t do much unless it’s compressed (small spaces or thicker layer of sorbothane). Would be really cool to have it precut.
I plan on it for R2. Right now I’m working with the manu to make sure R1 goes smoothly (should be shipping to me at the end of the month). I’m still in talks with them for my desires for future custom products to offer in R2.
I’ll keep everyone in the loop for what’ll be released in the future
Are these hard to cut ? the videos I saw on youtube of sorbothane seems to suggest they are pretty easy to cut. So wouldn’t it be possible to take a plate, put it on top of the sheet and cut the holes out ?
This is what I was thinking as well. Sure it would be nice to have affordable sheets that were pre cut to fit certain plate layouts. But given the huge cost @Manofinterests was quoted & how easy it would to just slap a plate on top of a sheet & use an exacto knife to trace it, I just don’t see the worth. Especially to those of us who will be using it. I personally don’t have any issue with DIYing a sheet for a build & suspect at least 90% of others will agree.