Lasercut Keyguard Instructions V0.1
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Laser Cut Keyguard Instructions This guide describes a workflow to assist a maker to design a custom lasercut keyguard for an Augmentative and Alternate Communication (AAC) device. An AAC device is used to help someone communicate. AAC devices may be comprised of a variety of different tablets, (tablet cases) and apps. The AAC apps may also provide options to customize the number, size and layout. A keyguard is a thin plate that sits over top of an AAC device. The keyguard can help a user use the AAC device more easily and more effectively. The openings in the keyguard can help provide focus, tactile feedback, and the ability to rest the user’s hand on the device without activating a button, reducing fatigue. Laser Cut Keyguard Overview The overall process involves measuring the users device, designing the layout of the Keyguard, preparing the vector file for Laser cutting, Laser cutting the Keyguard, and mounting the Keyguard. Equipment Creating a custom lasercut keyguard requires the following items: Computer with vector graphics software. o Inkscape o (Optional) Autodesk Fusion 360 Measuring Tools o Ruler o Measuring Tape Keyguard Material o Cardstock or cardboard to test fit o 1/8 in. or 1/16 in. acrylic Mounting o Suction tape These instructions will refer to steps in Inkscape, but alternative vector graphic software such as Adobe Illustrator or Corel Draw may also be used. 1. Gathering Device Information The first step is to gather information about how the user uses their device and then get the physical size of the device and app to create an appropriate keyguard. Usage Does the user want access to the on-screen buttons for editing, menu, iPad home button, etc., or is the keyguard to block access? What size and shape of openings are required? Should any additional information be marked on the keyguard? Version 0.1 www.makersmakingchange.com 2/12 Laser Cut Keyguard Device Measurements If the user’s device and AAC application is available, measurements can be made directly. In some cases, the user may submit a photo of the device with some measurements that can be used to scale and determine the measurements. Capturing A Reference Image To accurately measure the position of the various buttons, it can be helpful to capture a reference image. To ensure the final keyguard properly fits the device and the openings match the buttons, it is critical that the reference image can be scaled properly. To capture a reference image, accurately measure the cut a piece of paper to a length that spans the longest edge of the device. Accurately measure the length of the piece of paper and write it on the paper. It is important to know the distance of the screen opening to the closest milimeter or 1/16 inch. Take an image of the device with the app running and the piece of paper. Try to position the camera so the device is not skewed. If possible, capture a screenshot of the image as well. See the appendix for instruction on how to capture a screenshot of the app. Version 0.1 www.makersmakingchange.com 3/12 Laser Cut Keyguard Using The Reference Image In order to use a device photo to design the keyguard layout, the image needs to be rotated and scaled. Import Reference Image 1. Open Inkscape. 2. Select File > Import 3. Select the reference image. Press Open. 4. Press OK to use the default import options. Rotation Rotate the photo so that the tops and sides are aligned with the horizontal and vertical axes. Tip: Use the measuring tool (ruler icon on toolbar, or ‘M’ on the keyboard) to measure the angle of part of the image that should be horizontal. Scaling Scale the image so that the size of the image on the computer matches the size of the device. Use the measuring tool to measure the known distance in the reference photo. Change the units to match the known measurement. Calculate the required scaling factor by dividing the distance measured from the photo by the true distance measured on the device, then multiplying by 100. For example, if the distance measured from the photo is 25 inches and the true distance is 5 inches, the scaling factor is: 5/25 * 100 = 20% 1. 2. 3. 4. 5. Click Object > Transform Click on the Scale tab. Make sure the ‘Scale Proportionally’ is checked. Enter the scale factor calculated above. Click Apply to scale the image. 2. Version 0.1 Keyguard Layout www.makersmakingchange.com 4/12 Laser Cut Keyguard Design Considerations Message Window Size Settings Many AAC applications have a message window near the top of the screen. This message window may be adjustable to allow the user to set the number of lines and the text size. Changing the message window size affects the size of the buttons below. Increasing the number of lines or text size of the message window will cause the cause the buttons below to reduce in height. Camera Access Don’t cover the camera. Symmetry In some cases, it can be helpful to make the keyguard symmetric about a vertical axis so that the device can be rotated. Material Thickness Thicker keyguards may help reduce the number of accidental touches. Robustness Round the corners of the keyguard to remove the sharp edges. Try to avoid skinny section, especially near the edges, that may cause the keyguard to crack or break. Mounting How will the keyguard be mounted to the device? Keyguard Design Using the reference image as a reference, add rectangles and circles to match the outline and the openings for the keyguard. TIP: Use rectangles and circles and set the dimensions using the top bar. Marking Adding some laser etched marking can make the keyguard easier to use for the user, caregiver, or therapist, by helping identity for which app, device and/or user the keyguard belongs. One way to add text that is fast to etch as lines with the laser cutter is to use the Hershey Text plugin in Inkscape: Version 0.1 www.makersmakingchange.com 5/12 Laser Cut Keyguard 1. Extensions > Render > Hershey Text 2. In the Hershey Text dialog box: a. Type in desired text b. Select Action: Typeset that text c. Select Font Face: Sans-1 stroke 3. Click Apply. 4. Adjust the size and position of the text as desired. This will create a single-stroke vector path that can be quickly etched using the laser cutter. Use these steps to add “makersmakingchange.com” near an edge of the keyguard. In order to be legible, the text should be ⅛ inch (3 - 4 mm) in height. This will allow the user to locate the plans for a replacement or request a modification to their keyguard and provide an opportunity for other potential keyguard users to request their own keyguard. Customization / Personalization Add any additional information requested by the user to the keyguard. This may include, for example: Name Organization Phone number App / App setting Etc Try to position the text in a location so that it will not obscure the screen. The space on either side of the camera or Home button is usually a good choice. Laser Cutter File Preparation Once the geometry of the keyguard has been finalized, the next step is to prepare the design for laser cutting. These instructions may vary depending on the laser cutter and laser cutter software. Operation Stroke Fill Width Cut Line Red (R:255,G:0,B:0) None 0.01mm Engrave Line Blue (R:0,G:0,B:255) None 0.01mm Version 0.1 www.makersmakingchange.com 6/12 Laser Cut Keyguard Engrave Area None Black (R:0,G:0,B:0) 0 Cut lines are meant to cut through the entire depth of the material. The outside outline and all of the button openings should be set as Cut Lines. Engrave lines will engrave a line a limited depth. Single-line text markings should be set as Engrave Lines. Engrave Area will engrave a closed area. This can be useful for adding closed shapes, but takes longer to do on the laser cutter. Save the design file using the following naming convention: {FirstName}{LastInitial}{Number}_{Revision}.svg Save a copy as a PDF for laser cutting using the same naming convention: {FirstName}{LastInitial}{Number}_{Revision}.pdf For example, the initial design for John Smith’s first keyguard should be saved as: JohnS01_1.svg AND JohnS01_1.pdf Data Transfer Transfer both the SVG and PDF file to a USB flash drive. 3. Test-cut This is a recommended but optional step. Before cutting the keyguard out of plastic, it is helpful to test the fit to see how well the design matches up on the device and how well the openings match up to the buttons on the application. To quickly and inexpensively test the fit, we can laser cut the keyguard out of cardstock or cardboard. Laser Test Cut Bring the USB stick with the PDF design file to the laser cutter. Version 0.1 www.makersmakingchange.com 7/12 Laser Cut Keyguard Assessing Fit The keyguard should sit flat on the touchscreen. A little wiggle room is better than too tight. The openings should match up with the buttons Refinements If necessary, adjust the size and spacing so the keyguard fits the device and matches the buttons properly. 4. Final Cut Final Design Checks □ □ □ □ If possible, have you cut a design to test the fit? Are the corners rounded? Is the keyguard marked with makersmakingchange.com ? Is the keyguard marked with any requests from the user (name, app, etc)? Laser Cutting Bring the USB flash drive with the final design files to the laser cutter so the keyguard can be cut out of acrylic. 5. Finishing There are a few final steps to make the keyguard ready for use. Smoothing Check to make sure there are no sharp edges on the keyguard outline or any of the openings. A sharp knife or small file can be used to smooth over any sharp edges. Mounting There are a few different methods for mounting a keyguard on to an AAC device including: ● suctions cups ● velcro ● suction tape ● magnets ● under the case Version 0.1 www.makersmakingchange.com 8/12 Laser Cut Keyguard Suction tape (or "suction cup tape") bonds to smooth, flat, clean surfaces just like a suction cup. Though not actually suction cups, the surface of this tape has thousands of microscopic craters that work by creating many partial vacuums between the tape and the target surface. The tape is not pressure sensitive, can re-bond repeatedly, and leaves no residue on the target surface. To remove, you simply pull the tape off or twist it to break the bond. 1. Cut some narrow strips of suction tape. 2. Attach the strips of suction tape to the edges of the keyguard. Version 0.1 www.makersmakingchange.com 9/12 Laser Cut Keyguard Appendix iPad Screenshot Scaling To capture a screenshot on an iPad device, load the app and hold the device in the desired orientation. While holding down the On/Off button, press the Home button. The screen will flash to indicate a screenshot has been captured. The screenshot image will be 1024 pixels wide and 768 pixels high regardless of the actual size of the screen on the device. In order to scale it properly, use the conversion factor in the table below. iPad Type Screen Width (mm) Screen Height (mm) Conversion (px to mm) iPad 198.1 149 0.193 iPad2 198.1 149 0.193 iPad 3rd generation 198.1 149 0.193 iPad 4th generation 198.1 149 0.193 iPad 5th generation 196.47 147.39 0.192 iPad Pro 9.7-inch 203.11 153.71 0.198 iPad Pro 10.5-inch 213.5 160.13 0.208 iPad Pro 12.9-inch 1st Generation 262.27 196.61 0.256 iPad Pro 12.9-inch 2nd Generation 262.27 196.61 0.256 iPad mini 161.2 121.3 0.157 iPad mini 2 161.2 121.3 0.157 iPad mini 3 161.2 121.3 0.157 iPad mini 4 161.24 121.31 0.157 iPad Air 198.1 149 0.193 iPad Air 2 203.11 153.71 0.198 Source: http://volksswitch.org/index.php/volks-devices/fully-customizable-3d-printable-aackeyguard-for-tablets/using-app-screenshots-to-determine-the-app-layout/ Version 0.1 www.makersmakingchange.com 10/12 Laser Cut Keyguard Fusion 360 Workflow Autodesk Fusion 360 is a cloud-based, computer-assisted design program with a free license for hobbyists and enthusiasts. Fusion 360 requires a 64 bit system and either Windows or MAC OS. To access the hobbyist license, you’ll need to sign up for an account and download the free trial: https://www.autodesk.com/products/fusion-360/overview Fusion 360 has a few features that make it a useful tool for designing custom laser cut keyguards. Insert Canvas 1. Under the insert menu, select Insert Canvas 2. Choose the top plane 3. Select the image 4. Rotate the image to align the edges with the grid. You may need to manually enter a small value (e.g. 1, 0.1 degrees) into the box. Scale the Image 1. In the Browser bar, click the triangle beside the Canvasses Folder to show its contents 2. Right click on the canvas image you added in the previous step and select ‘Calibrate Image’ 3. Use the mouse to select a first and a second point on the image with a known distance between them, and then enter the distance value in to the dialog box. Try to be as accurate as possible when entering the points so the reference image is scaled properly. Design Keyguard Layout 1. Create a new sketch on the same plane as the canvas. 2. Create the outline of the keyguard using the rectangle tool. 3. Create the keyguard button openings using rectangles or circles according to the users preference. 4. When finished, close the sketch. Tip #1: Use construction lines to help align the openings. Tip #2: To make the design symmetric, add a construction line in the middle and use the Sketch>Mirror tool to copy openings to the other side. You can also use Symmetry constraints to enforce symmetry. Extrude Keyguard Sketch 1. Click Create > Extrude 2. Select the keyguard profile sketch. 3. Set the extrusion distance to 1/16 inch or 1/8 inch Export sketch Version 0.1 www.makersmakingchange.com 11/12 Laser Cut Keyguard 1. Right click on the sketch 2. Click ‘Save as DXF’ Import sketch into Inkscape 1. Import the dxf file. 2. In some cases the design may be upside down. You may need to rotate the design 180 degrees. 3. Add any marking or text. 4. Change the line color and stroke according to the laser cut file preparation instructions. Additional Resources Suction Tape http://www.keyguardat.com/suction-tape/ 3D Printed Keyguard Workflow http://volksswitch.org/index.php/volks-devices/fully-customizable-3d-printable-aac-keyguard-fortablets/ Version 0.1 www.makersmakingchange.com 12/12
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