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PolyKybd

PCB & Gerber Files

The PolyKybd uses two 4-layer PCBs (left and right), each 1.6mm thick. The PCBs contain a large number of fine-pitch SMD components including the RP2040 microcontroller and 72 FPC sockets, so ordering pre-assembled PCBs is strongly recommended.

Assembled PCB

A bare board as it arrives from the fab — this is the rev3.2 left PCB, matching the gerbers below. One side carries the RP2040, the two USB-C connectors and the 72 FPC sockets:

Bare left PCB, showing the RP2040, USB-C connectors and the rows of FPC sockets

The other side carries the switch footprints and the RGB LEDs:

The same board reversed, showing switch footprints and RGB LEDs

Gerber files

Section titled “Gerber files”

The latest gerber files, BOM, and pick & place files are in the PolyKybd hardware repo:

File Description
poly_kybd/Gerber/PCB/left-side-v3.2/PolyKybd_Split72_L_3.2.zip Left PCB gerbers
poly_kybd/Gerber/PCB/right-side-v3.2/PolyKybd_Split72_R_3.2.zip Right PCB gerbers

Aluminum plates

Section titled “Aluminum plates”

The key plates are also ordered as PCBs — specify 1.2mm aluminum when ordering:

File Description
poly_kybd/Gerber/Plate/gerber-left-side-v3-17.11.2023.zip Left aluminum plate
poly_kybd/Gerber/Plate/gerber-right-side-v3-17.11.2023.zip Right aluminum plate

The two plates are mirrored — one per half. Each switch cutout is square; the larger opening takes the expansion slot part:

Aluminum plate for one half, with the square switch cutouts and the larger expansion-slot opening

The mirrored plate for the other half

Ordering from JLCPCB

Section titled “Ordering from JLCPCB”

JLCPCB is one convenient option that supports both PCB assembly and aluminum PCB orders.

  1. Upload the gerber ZIP for the PCB
  2. Select 4-layer, 1.6mm thickness
  3. Enable PCB Assembly and upload the BOM and CPL (pick & place) files from the Gerber folder
  4. If the fab offers a parts orientation verification step, use it — part orientation in KiCad may differ from the fab’s default

KiCad source files

Section titled “KiCad source files”

The full KiCad 7 projects are in the repo if you want to make your own modifications:

  • poly_kybd/poly_kybd_split72_right.kicad_pro — Right PCB
  • poly_kybd/poly_kybd_split72_left.kicad_pro — Left PCB
  • poly_kybd/poly_kybd_split72_plate_right.kicad_pro — Right plate
  • poly_kybd/poly_kybd_split72_plate_left.kicad_pro — Left plate

See PCB & Case Modification for more on working with the KiCad sources, and Electronics & Schematics for an annotated tour of the board.