60% Keyboard PCB-How To Build

What is a 60% Keyboard?

A 60% keyboard is a compact keyboard layout that omits the number pad, function keys, and navigation keys found on a standard full-size keyboard. It typically has around 61 keys, hence the name “60%”. This smaller size makes 60% keyboards very portable while still retaining all the essential alphanumeric keys.

Some of the benefits of a 60% keyboard include:

• Takes up less desk space
• More ergonomic positioning for mouse
• Easier to transport
• Minimalist, sleek look
• Highly customizable

The tradeoff is you lose dedicated keys for arrows, functions like F1-F12, and the number keypad. These functions are still accessible but require holding down a function key to use as a layer.

Planning Your 60% Keyboard PCB Design

Choosing a Keyboard Layout

The first step is deciding on the physical layout and size of your PCB. The most common 60% layouts are:

Layout	Keys	Spacebar	Description
GH60	61	6.25U	Standard 60% layout, very common
XD60	64	2.25U/2.75U split	Adds dedicated arrow keys
Poker	61	7U	Uses larger spacebar
HHKB	60	Split with blocked corners	“Happy Hacking Keyboard” layout

Whichever layout you choose, find or create a plate file (usually in .dxf format) that matches the physical dimensions and cutouts needed. This will be used to check your PCB design.

Key Switch Type

You’ll need to choose what type of mechanical key switches your PCB will support. The 3 main types are:

Type	Mount	Pins
MX	Plate or PCB	2 contacts and 2 plastic pins
Alps	Plate	2 contacts
Kailh Choc	PCB	2 surface contacts

Your choice here will determine the footprints needed for the switch holes on the PCB. MX switches are by far the most common.

Electrical Design Considerations

For the electronics, the main components you’ll need are:

• Microcontroller (MCU) – runs the firmware that registers key presses. Popular choices are the Atmega32U4 or STM32 series.

• Resistors – each switch needs a resistor, typically 1k to 10k ohm.

• Diodes – each switch needs a diode to prevent “ghosting” when multiple keys are pressed. 1N4148 signal diodes are usually used.

• USB connector – for connecting the keyboard to a computer. USB-C is becoming more common over micro-USB.

• USBASP header (optional) – makes it easy to flash the firmware

• Reset switch (optional) – for quickly resetting the keyboard

You can use an existing 60% keyboard schematic as reference for designing your circuit. The key is having a matrix where each key switch connects a unique row and column, with a diode in series. The MCU will scan the matrix to detect when keys are pressed.

Other considerations are whether you want LEDs for backlighting or underglow, and if you want the USB port to be detachable or not.

Designing the PCB in CAD Software

Schematic Capture

With the circuit planned out, the first step is drawing the schematic in electronic design automation (EDA) software. Some popular cross-platform EDA options are:

• KiCad
• EasyEDA
• Diptrace

Start by creating symbols for each component and then wire them up exactly as your hand-drawn schematic. It helps to use net labels to keep track of the connections.

Be sure to add values for all components and specify the diode direction. Also fill in the USB connector pinout according to your MCU’s datasheet.

PCB Layout

With the schematic done, now it’s time to layout the physical PCB. Some tips:

• Import your plate file on the Edge.Cuts layer and place switch footprints to match the cutouts exactly.

• Align components on a 0.1″ grid to make soldering easier.

-Place the MCU and USB port on the back side, opposite of the key switches.

• Pour copper fills on the top and bottom layers and stitch them together with vias to improve shielding.

• If doing underglow LEDs, leave a large unmasked area on the back side so the light can shine through.

• Give the PCB unique graphics, an icon, and your name to personalize it!

Route all the traces, ensuring good clearances between different nets. Trace width isn’t too critical for the low-speed signals – 10 to 20 mil is typical. Wider is better for the power traces.

Manufacturing the PCB

Once your design is finished, generate Gerber files and drill files according to your PCB manufacturers specifications. Most fabs accept the default KiCad settings.

There are many PCB fabs to choose from with varying lead times and costs, such as:

• JLCPCB
• ALLPCB
• OSH Park (smaller qty)
• PCBWay

Upload your Gerber/drill files, choose your PCB options, and place your order. Typical specs are:

• 1.6mm PCB thickness
• ENIG (gold) or HASL surface finish
• Green soldermask
• 1 oz copper weight

Don’t forget to order a stencil if you plan to assemble with solder paste! Assembling the PCB Once you receive your PCBs, you can start soldering! A good soldering order is:

1. Start by soldering all SMD components (resistors, diodes, MCU). Tweezers help place them.

2. Solder the through-hole components (USB port, switches. USBASP header, etc.)

3. Do a thorough visual inspection for any missing joints or solder bridges.

4. Test the PCB for shorts with a multimeter before applying power.

5. Flash the firmware.

6. Solder in switches and LEDs last.

7. Optionally, apply foam to the bottom of the PCB for sound dampening.

Some equipment that makes assembly easier:

• Soldering iron with adjustable temperature
• Brass sponge tip cleaner
• Solder sucker
• Flux pen
• PCB vise

Take your time and enjoy the build process!

Firmware for Your 60% Keyboard

The last step is flashing the firmware. The two main open-source firmware options are:

• QMK
• TMK

You’ll need to download the source code and modify the keymap, build settings, and compile according to your 60% keyboard’s specifics.

Then, to flash you can either:

• Use the USBASP header and external programmer
• Directly via USB with a bootloader (requires setting fuses)

The bootloader method is more convenient for trying out new keymaps. Once flashed successfully, test out each key and get to typing on your new creation!

FAQ

How much does it cost to build a custom 60% keyboard PCB?

PCBs usually cost under $10 each in medium quantity (10-20). Components like the MCU, resistors, diodes, USB port, and key switches can add up to around $30-60 depending on your exact part choices. Of course, you also need to factor in the case, keycaps, shipping time and cost to get a realistic budget.

How long does it take to design and build?

Designing the PCB can take anywhere from a few hours to a few weeks depending on complexity and your comfort with the EDA tools. Cheap PCBs usually arrive 2-3 weeks after ordering. Then assembly can be done in an evening or two. So in total, building a 60% keyboard from scratch typically takes about a month start to finish.

What if I’ve never designed a PCB before?

Everyone starts somewhere! There are many resources available to learn PCB design. SparkFun and Adafruit have great tutorials. For specific 60% keyboard PCB Design Tips, check out:

• ai03 PCB Designer Guide
• Masterzen’s Key64 Tutorial
• Keyboard PCB Guide by Ruiqimao

Start with an existing 60% project and make small tweaks to learn. There are also many friendly people on the mechanical keyboard Discord servers and forums willing to help beginners.

Are there any easier alternatives to a fully custom PCB?

Yes, you can get a predesigned “universal” 60% PCB and still do a customized build with your own switches, layout, and case. Some popular PCBs are:

• DZ60
• GH60
• 1up HSE

These come as kits with most of the SMD components pre-soldered. You just need to add switches and flash. It’s a great compromise between customization and difficulty.

What’s the best way to learn PCB design for keyboards?

Practice! Start with small mods and work your way up to a full board:

1. Hand-wire a macro pad or numpad
2. Assemble a predesigned PCB Kit
3. Create a custom layout in KLE and hand-wire it
4. Design a macro pad or numpad PCB from scratch
5. Modify an open-source 60% PCB like the Voyager60
6. Design your own 60% PCB from the ground up!

Don’t get discouraged if you make mistakes along the way – it’s part of the learning process. And remember, the keyboard community is very supportive and there are always people happy to help troubleshoot issues.