Redox Handwire V5 Step 1: Brainstorming
I have built four versions of the Redox Handwire, making multiple copies of each. My V4 has been my daily keyboard for over a year. It works well, but fixing problems on it is hard.
Loose wires inside the case can still shift and touch. Over time, the switch sockets near the edges also push downward as you type.
For V5, the goal is a stable build that lasts. Instead of running loose wires through the air, all sockets, diodes, and wires will sit inside printed channels in the plate. It is basically a 3D-printed circuit board.
The Flush Mid-Plate
I started with a single switch to test the idea.
Initial test: A middle plate holding the socket and diode flat under the top plate.
I placed a printed middle plate directly under the switch plate. It has small pockets to hold the socket and diode. The switch pins plug straight into the socket. The plastic holds both parts tightly, so the solder joints do not carry any weight.
Parametric Switch Profiles
Drawing every switch from scratch wastes time.
Parametric design: The 3D model updates when changing switch types.
I set up the 3D model so dimensions update automatically. It supports Kailh Choc V1, Choc V2, Gateron KS-33, and standard MX switches. Changing one setting adjusts the hole sizes, pin gaps, and pocket depths. This lets me test different switches easily.
The 2x2 Matrix Grid
Testing one switch does not show how a full keyboard fits together.
A 2×2 grid to test switch spacing and wire paths.
I arranged four switches in a 2×2 grid with standard 19.05 mm spacing. This showed how wires need to run between keys. It was clear that rows and columns need dedicated paths so wires stay organized.
The Tray-Loaded Grid
Stacking loose plates made assembly tricky to line up.
A bottom tray that holds the sockets and diodes in place.
I combined the parts into a solid bottom tray. The pockets for sockets and diodes are built right into the floor. The top plate and spacer drop down over them, clamping everything together. This keeps parts from shifting when screwing the case shut.
The Dual-Layer Skeleton
If row and column wires cross on the same level, they can touch and short out.
Two wire levels: Columns run on the bottom, rows run on top.
I split the wire paths into separate levels. Column wires run along the bottom floor. Row wires run along the top floor. A thin plastic wall sits between them. Small holes let connections pass through only where needed. The wires can never touch.
Multi-Layer Plate Stackup
The final design uses three main parts:
- Top Plate: Holds the switches firmly in place.
- Spacer: A 1.4 mm layer that fills the gap between switches and sockets.
- Bottom Tray: Holds the sockets, diodes, and wire channels on separate levels.
Bare copper wire presses straight into the printed grooves.
Next, I looked at switch choices and physical sizes in Step 2: Testing and Selecting Switches.