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Show HN: Bayleaf – Building a low-profile wireless split keyboard (graz.io)

735 points by sgraz ↗ HN
Hey HN,

I built a wireless, split, ultra-low profile keyboard from scratch called Bayleaf. As a beginner I learned all things electronics, PCB-building, designing for manufacturing, and many other hardware-related skills to put this together.

This case study dives into the build process and of course the final result, hope you enjoy!

257 comments

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mattpavelle
I love this. Well done. I've looked in the past for an ultra portable full sized keyboard (with a nice aesthetic) that I could throw in my pocket. I wonder if I could actually do any real work (not coding, of course) at a coffee shop with my iPhone in a stand and with a keyboard like that.
aredox
Nice write-up.

For something so thin, your soldering woes aren't surprising. The standard way to manage that would have been to solder everything in one go on a hot plate (reflow soldering).

https://www.youtube.com/watch?v=QarizoUnRfk

stronglikedan
> reflow soldering

one of the most satisfying things to watch

ghostly_s
This video features the exact same technique and hot plate that was used here.
sgraz
Thank you, My first few attempts were with a SMD stencil and a 50x50mm hotplate, it's true that maybe a larger hotplate that could span the whole PCB might have done a better job. But with the smaller plate it was "easier" to just manually apply solder paste and do 4 switches at a time.

I think this method is also highly specific to these switches. They are known for being difficult to solder with hobby-tier equipment.

shellfishgene
I just reflowed a board in a cheap cast iron pan filled with some sand on my induction stove. Worked fine!
snide
This is beautiful. I'm a "Let's Split" style keyboarder as well so this made me giddy! There's a distinct lack of solid cases out there for this layout style.

You mention possibly mass producing the next round. Please add a notify email list or something. I'd be all over this.

__mharrison__
I think cases are the biggest issue with DIY keyboards.

The plastic laminate of my ergodoxen was stiff, sturdy, and heavy. The exposed bolts were a little industrial. Very much had a DIY look.

My Lily58 started out with the PCB "case" which is horrible. Way too flexible, and switches falling out as soon as you attempted to transport it. (Easy transport was my main motivation for the smaller keyboard.)

Eventually, I was able to convince someone on Etsy to print me a 3d case for it. It is ok. Much better than the PCBs. However, switches still have a tendency to pop out when moving the keyboard.

The case on the Bayleaf makes me wonder if other keyboards could do a better job with case offerings.

I've always gone with wired keyboards because dealing with batteries seems annoying.

Looking at this keyboard makes me realize that I've optimized for functionality but this beauty is optimized for form.

jsheard
3D printed cases do vary in quality quite a bit, something made with a cheap consumer FDM printer won't be nearly as nice as a resin SLA or nylon MJF/SLS case printed on an industrial-grade machine and professionally finished. The latter processes are pretty accessible these days from companies like JLCPCB or PCBWay.

You can even get them to 3D print metal parts with an SLM process, although that's on the pricier side.

Palomides
>do a better job with case offerings

for hobby businesses like most of these weird little keyboards, adding $200 to the parts cost is a real stretch, considering their already niche appeal and limited capital for investment

__mharrison__
Folks are already paying $200+ for these keyboards. Some pay $50+ for a single keycap.
azthecx
Quite neat result and presentation! Can you estimate what did your research and final product cost turn out to be?
sgraz
Final product, i.e only the parts and components were $400.

The cost of all the tools and software I did not track but I would guess I invested somewhere around $1K which includes software licenses, shipping, new tools etc.

But I find tracking the cost of research a bit impractical as it doesn't include indirect costs like billable hours that I technically could have spent on clients etc.

nicksergeant
I've wanted this for years. I've tried so many "ergonomic" mechanical keyboards, but the huge key travel (even if very soft switches), tends to always give me finger/wrist issues over a few weeks.
nicksergeant
>> Can I buy this keyboard? > Negative, this singular prototype is not for sale.

:sobbing:

I hope someone builds / sells this! Instant buy for me, if so.

abound
But then, the next question down:

> Are you planning to sell this keyboard at scale?

> Dependent on the reception, likely yes. But it wont be exactly this design. A second iteration is in the works with improved sound profile and ergonomics. Stay tuned.

stronglikedan
I had all those issues too, until I remembered my high school typing class where the teacher would slap our wrists with a ruler if they were resting. Now I lift my wrists like I was taught, and use non-split keyboards with better results than I used to get with splits.
unitexe
To reduce mouse hand travel I got a roller mouse pro slim about 6 months ago. Not great for fine motor tasks but exceptional for other general uses. Alleviated a lot of pain in my hands and fingers.

I use this with a small slim keychron keyboard and with a kinesis advantage 360.

The roller seems to be getting a bit sticky after 6 months of heavy use and transporting it between work and home. Nonetheless, would get another in a heartbeat.

Perhaps worth a look?

unitexe
I keep my Logitech MX close cause the infinite scroll is just too damn good. But the MX kills my hands when using for prolonged periods.
jacksontheel
Roller mice are great. I also set up my keyboard such that I can hold down a key and use WASD to move my mouse, with J being left click and K being right. That's been a game changer for me, too.
lycopodiopsida
There is always Glove80, choc switches have very little travel.
jsheard
Eh, Choc switches have less travel than MX switches but I wouldn't say they have very little travel. Chocs main selling point is the form factor which allows the keyboard chassis to be much thinner. MX switches usually have 4mm of travel, Choc switches have 3mm, while the PG1316S switches used in OPs keyboard only have 1.8mm. I think Apples current switches are even shallower at ~1mm.
nicksergeant
Yeah. The travel on the Apple Magic Keyboard, which I can't seem to pry myself away from, is around 1.15mm.
jjani
I'm convinced the Macbook keys are different from the Magic Keyboard (my joints say so) and have significantly lower travel.
jjani
> while the PG1316S switches used in OPs keyboard only have 1.8mm

Do you happen to know of a resource around this topic? I'd love to know what the actual lowest travel switches are. In my experience it's the Macbook's.

tomlong
This looks really good. As a happy ergodox-ez user of a few years, I would buy one of these in a heartbeat.
zaruvi
Looks really nice. I do have my doubts about the ergonomics of it though. Once you've had a taste of concavity and column-staggering nothing else feels the same.
carb
That's how I feel about keyboard tilts away from a full pronation/flat and towards a neutral position. Once I switched to having a rotated split keyboard, my forearms and wrists felt incredible, and I hadn't even considered them uncomfortable before.
slama
I wonder if they could fit a simple flip-out stand for some tilt without too many compromises
derac
"pain grid", Freudian slip? lol
2wrist
This is gorgeous! well done.
wnolens
It's gorgeous. Impressive execution - looks like a polished product from Apple.
whalesalad
Beautiful design, great execution. All-in-all this is a wonderful project.

However... ever since transitioning to an ergonomic/curved keyboard I don't think that I could ever go back to a traditional layout, even moreso for ortholinear.

ge96
I feel both ways, I use an apple wireless keyboard (flat) and a Durgod Hades 68 (curved mech). I don't like the felt keycaps/no letters on this one but yeah the build is amazing especially saying they're a beginner damn.

edit: I'll note I prefer the 65-68% keyboards where it has the dedicated arrow keys

hhheath
sensational. well done!

one feature I would really like to see is multi-device connectivity/switching like the Logitech MX Keys. Outside of that, this keyboard is my grail board. Looking forward to keeping up with this project!

wucke13
I think ZMK (available on the Nice!Nano) does exactly that already?
memhole
Wouldn’t even know it’s not a professional product. Great write up too
UI_at_80x24
OP, congrats on the product and effort. _NOTHING_ beats prototyping and building.

For other split-mechanical keyboards check out:

ZSA Voyager

Moergo Glove 80

w10-1
Also, should you prioritize ergonomics over function or form, the Kinesis Advantage 360 Professional
porkloin
Not sure if you're familiar with it, but Glove80 which the parent comment you were replying to is very similar to Kinesis boards (concave keywell, staggered columnar layout, etc.) but leverages a lot of the open source stuff like ZMK firmware that Kinesis doesn't support https://www.moergo.com/

Edit: nevermind, I just learned that the advantage360 pro uses ZMK as well. Either way, they both seem like great options for people who prioritize the ergonomics over aesthetics :)

okayishdefaults
Why stop there when you could go for a Charybdis and get the purer form of zmk and a trackball option
cole-k
Yeah this is awesome.

For keyboards really similar to OP's

The keyboard they were inspired by (not for sale... yet?): https://old.reddit.com/r/ErgoMechKeyboards/comments/1cfg3vr/...

Corneish (out of stock): https://lowprokb.ca/products/corne-ish-zen?variant=376943319... Unicorne: https://new.boardsource.xyz/products/unicorne-LP

The corneish is an absolute gem in my opinion. It is possibly (probably?) open-sourced too.

ValentinPearce
The mikefive is my dream work keyboard. It's two keys extra from what I have currently but I know I can find something to do with the extra cluster keys
johncalvinyoung
less specifically like OP's, but a really great product that I and a bunch of my coworkers use: the 'Ultimate Hacking Keyboard' 60 (typically referred to as a UHK). I have mine with the palmrest and the recent riser accessory, so I use it split and tented for less wrist/forearm tension.
szvsw
I have the ZSA Moonlander and absolutely love it! Definitely recommend it!
tortilla
I have the voyager and I'm really very happy with it. No wrist pain when I'm typing a lot.

https://imgur.com/pklEZSh

Ambients Silent Choc Switches (20g Linear), keycaps from worklouder (Pure)

droctothorpe
Gorgeous! How do the worklouder pures compare to the stock keycaps?
tortilla
I wasn't sure how I would like the keycaps when I ordered it. Hard to describe but they feel better than the stock keycaps (with the silent switches) and sound a little better when I strike the plastic keycaps. The stock keycaps have a slight hollow sound (if I recall correctly).
jacksontheel
This looks incredible, I was hoping when I clicked that it would be ortholinear, pleasantly surprised it is! Probably about four years ago I bought a ZSA Moonlander, and started learning Vim keybindings right at the same time. My words per minute dropped to 20 or something before climbing back and passing what it was before. I couldn't ever go back.
gatkinso
Beautiful work, loved reading about your process.
__mharrison__
Looks beautiful. Congrats. A jedi builds their own lightsaber...

(Typed on a Lily58)

seemaze
Bravo! You have elevated a honed tool to a truly engaging artifact! I think the large challenge in design is mitigating the breaking point between ruthless efficiency and endearing novelty.

I picked up a Let's Split v2[0] when it came out years ago and never soldered it up.. maybe it's time!

[0]https://shop.beekeeb.com/product/lets-split-v2-keyboard-pcb-...