This is a reverse engeneered design of the Azeron Cyborg II. There are 30 programmable switches and one analog joystick. It runs on an Adafruit KB2040 board with an Adafruit MCP23017 GPIO expander for more pins to connect switches to. The boards are programmed via CircuitPython. The keybinds for each switch and joystick can be changed in the settings.

Printed on a Prusa CORE One in Prusament Galaxy Black and Silver as well as Filamentum Signal Red. The keycaps were printed with a 0,2 mm layerheight on a structural setting. All the other parts were printed with a 0,25 mm layer height and a speed setting. Only the Switches, the Thumb-Main base and the Palmrest need Supports. The Palmrest was printed laying on its longer side for minimal supports. 

Hardware used:

Electronics:

• Adafruit KB2040

• Adafruit MCP23017 GPIO Expander

• PS2 Controller Joystick module

• Adafruit 5-Way Navigational Joystick

• Daokai Microswitches

• Fermerry 0,05 mm² wire (6 Colors)

• Heatshrink

Fasteners:

• Screws:

  • BH M3 x 6 mm

  • BH M3 x 8-10 mm

  • CS M2,5 x 10 mm

  • RH M2,5 x 6 mm

  • RH M2,5 x 12 mm

  • RH M2,5 x 8 mm

• Heat-Set-Inserts:

  • Dayalo M2,5 x 3,5 x 4 mm

  • 23x CNC Kitchen M3 made for VORON

Miscellaneous:

• Magnet N52 10 x 2 mm 

• Neopren fabric coated 5 mm 

Tools:

• Must have:

  • 3D-Printer :)

  • Soldring Iron

  • Screwdriver Hex 1,5 & 2 mm

• Optional:

  • Helping hand (helps a lot)

  • Vareity of Files for cleaning the 3D-Prints

  • Tweezers

  • Deburrer / Countersinking-bit

  • Glue for magnets and Neopren

Assembly:

1. print all parts 

2. install Heat-Set-Inserts

3. sand parts for matching mating surface (optional)

4. Tip: dry run the Assembly of all towers and joystick before Soldring any switches to check clearance of the switches as well as to avoid any binding

5. All switches are connected to a common Ground for each tower and the joysticks. They are wired in parallel.

6. Wire and solder the components (wiring diagram). Be aware of the fact that some wires have to be routed through 3D-printed parts before they are connected to the next switch.

7. Close up the Towers (be sure to place the switches before putting on the other halve, because they can not be put in afterwards).  The Order of the switches from top to bottom is: top, front, (side), middle, back and rear.

8. Assemble the Base Components and screw down the Towers in the furthest position to ensure sufficent wire lenght

9. Rout wires through the holes in the electronics housing and connect to the boards (wiring diagram)

10. Glue Neopren and Magents to Palmrest and Electronics Housing.

11. Plug in a USB-Type C cable into the KB2040 while pressing the boot button. It should be detected as a RP1-RP2 drive. Install Circuit Python (Adafruit KB2040 Download) on the board (Just click the Download .UF2 Now).

12. Install Adafruit HID and MCP23017 Librarys onto the device. To do so, download the 9.x Library Bundle from Libraries and copy adafruit_HID and adafruit_mcp230xx into the lib folder.

13. create or copy code.py and settings.py onto the device. Press the reset button to restart the board.

14. Finished! Enjoy your new Cyborg like keypad :) 

This is still a WIP, so please comment on any improments you might want to see.