How to Design and 3D Print Custom Mechanical Keyboards

Mechanical keyboards have grown from niche hobby to full-blown obsession, especially among makers who value performance, customization, and aesthetics. Thanks to 3D printing, it’s now easier than ever to design, prototype, and build your own custom mechanical keyboard—exactly how you want it.

Whether you want an ergonomic split layout, a compact 40% board, or a one-of-a-kind keyboard with a transparent case and sculpted keycaps, this guide walks you through every step of the process: from design to 3D printing to final assembly.

Let’s explore how to bring your keyboard ideas to life with 3D printing and a bit of hardware know-how.

Why Build a 3D Printed Keyboard?

3D printing opens up complete creative freedom. You’re no longer limited by the layouts, shapes, and aesthetics offered by commercial keyboards.

Benefits of 3D Printing a Custom Keyboard:

• Tailored ergonomics to fit your hand and posture
• Full control over layout, key count, and spacing
• Unique visual designs using transparent, textured, or multi-material cases
• Cost-effective prototyping for layout experiments
• Limitless customization with open-source firmware

If you’re into keyboard modding, CAD design, or even casual DIY, building a 3D printed mechanical keyboard is the ultimate project.

Step-by-Step Overview

Here’s a high-level summary of the full process:

1. Define your layout and features
2. Design the case in CAD or use existing models
3. Choose your switches, PCB, and controller
4. Design or import the plate and mounting system
5. 3D print the case and test fit
6. Assemble the keyboard with electronics
7. Flash firmware and test
8. Customize with keycaps, lighting, and finishing touches

Let’s go into detail on each step.

1. Define Your Keyboard Layout

Before touching any 3D modeling tools, decide what kind of keyboard you want to build.

Key Questions:

• How many keys do you want? (60%, 75%, TKL, full-size, ortholinear, split)
• Do you want a number pad, arrows, or macro keys?
• Do you need wireless support or USB-C?
• Will the case be one-piece or split?
• Do you want hot-swap support?

Tools to Help:

• Keyboard Layout Editor (KLE) – design and export your layout
• Keymap Drawer – visualize and document layouts
• Save your layout as a .json file for use in CAD and firmware.

2. Design the Keyboard Case

Once you have your layout, it’s time to create the physical design.

Tools for 3D Modeling:

• Fusion 360 – best for parametric CAD and mechanical design
• FreeCAD – open-source and versatile
• TinkerCAD – for simple models and beginners
• OpenSCAD – script-based modeling, ideal for split keyboards

Design Considerations:

• Top and bottom shell or a one-piece case
• USB port opening (typically USB-C)
• Screw mount locations
• Internal supports for the PCB or plate
• Room for controller and wires
• Optional battery space for wireless builds

You can also base your design on open-source models from:

• Thingiverse
• Printables
• Github keyboard repos

Tip: Split keyboards (like Dactyl or Corne) often use curved or sculpted cases with finger-specific key wells. These can be customized in OpenSCAD or imported into Fusion 360.

3. Choose Switches, PCB, and Controller

Your mechanical keyboard’s feel and functionality rely on the components you choose.

Switches:

• MX-compatible switches (Cherry, Gateron, Kailh, etc.)
• Choose based on actuation force, sound, and travel
• Plate-mount or PCB-mount options

PCB Options:

• Custom PCBs (open-source like Corne, Lily58, Reviung)
• Prototyping with stripboard/perfboard
• Hand-wiring for small or curved designs

Microcontroller:

• Pro Micro (ATmega32u4) – common and inexpensive
• Elite-C – USB-C version of Pro Micro
• RP2040 boards (like Raspberry Pi Pico) – faster, more pins
• Nice!Nano – for wireless (BLE) support

Make sure your controller is compatible with QMK or ZMK firmware.

4. Design or Import the Switch Plate

The switch plate holds your switches securely in the case.

Options:

• 3D printed plate – easy to customize, but can flex under typing
• Laser-cut metal or acrylic plate – rigid and precise, but needs external service

Use Swillkb Plate & Case Builder to generate a plate design from your layout. Export as DXF or SVG for importing into CAD.

Mounting Styles:

• Plate mount (switches snap into plate, PCB sits underneath)
• Tray mount (PCB mounts to case, no plate needed)
• Top mount, sandwich mount, or gasket mount (advanced designs)

5. 3D Print the Case

Print Settings:

Tips:

• Use a well-tuned printer to ensure flat mating surfaces.
• Print the bottom shell with heat tolerance in mind if using USB or battery.
• Use TPU feet for non-slip grip.

6. Assemble the Keyboard

Now it’s time to bring everything together.

For Plate-Mounted Builds:

1. Snap switches into the plate.
2. Place PCB below and solder each switch pin.
3. Insert stabilizers (for longer keys like space or enter).
4. Screw the PCB and plate assembly into the printed case.

For Hand-Wired Builds:

1. Insert switches into the case or plate.
2. Solder diodes to each switch.
3. Wire all columns and rows using solid-core wire.
4. Connect to microcontroller with labeled pins.
5. Insulate with heat shrink or electrical tape.

Testing: Use QMK Configurator or Via to map and test key presses.

7. Flash and Customize the Firmware

Most custom keyboards use QMK (wired) or ZMK (wireless) firmware.

QMK (Quantum Mechanical Keyboard Firmware):

• Highly customizable
• Supports macros, layers, tap dances, OLED displays, and more

Tools:

• QMK Toolbox – For flashing .hex or .bin files
• QMK Configurator – Web interface for layout setup

Flash Process:

1. Set up QMK CLI or use pre-built .hex files.
2. Put the controller into bootloader mode.
3. Flash the firmware using QMK Toolbox or terminal.
4. Verify keymaps and test all functions.

8. Add Final Touches

Keycaps:

• Choose MX-compatible keycaps in your preferred profile (e.g., Cherry, DSA, SA)
• Consider printing your own using resin printing (for high detail)
• Customize with labels, colors, or blank caps

Lighting (Optional):

• Add RGB strips or underglow using WS2812B LEDs
• Configure lighting effects in QMK or ZMK
• Use transparent cases for aesthetic lighting

Accessories:

• Custom USB cable
• Carrying case
• Magnetic covers or wrist rests (printable)

Common Challenges (and How to Solve Them)

Where to Find Inspiration and Resources

Projects and Repositories:

• Github – Awesome Mechanical Keyboards
• Reddit: r/MechanicalKeyboards
• r/ErgoMechKeyboards
• Keeb.io
• SplitKB

Open-Source Models:

• Corne (split)
• Lily58 (split)
• Dactyl Manuform (sculpted split)
• Reviung (single-piece low-profile)

Many of these have STL files, wiring guides, and firmware pre-configured.

Conclusion

Designing and 3D printing your own custom mechanical keyboard is one of the most satisfying projects for any maker or tech enthusiast. It combines mechanical design, electrical engineering, 3D printing, and firmware—all in one build.

From compact travel keyboards to ergonomic masterpieces, the options are limitless. With the right tools, planning, and patience, you can create a truly one-of-a-kind typing experience that matches your style, needs, and creativity.

Now that you know the full process, it’s time to grab your favorite CAD tool, choose your switches, and bring your perfect keyboard to life.