Make your own keypads

You can make your own keypads using the following steps.
Or alternatively, if we can add 10 hours to Bob’s day and get enough interest maybe we can convince him to come up with one or two DIY kits.

See: attached schematic of components needed.
I used aluminum foil duct tape from Home Depot.

#1 (Overlay) design whatever keypad layout you need. I use SketchUp to do this.
Make sure your overlay matches your PCB keypad pattern.
Print this on 24 pound paper and laminate both sides.
#2 (Mask) make a similar layout as in #1.
Place centered 1/4 inch circles in key pad. Print this on 110 pound card stock paper.
Put two pieces of 110 pound paper behind this mask, punch out the circles in each keypad.
#3 make a PCB using pattern similar to this one or like the one in image #4 (I used the #3 pattern)
#5 place your punched out mask over your PCB (here I made a mask out of plastic and cut out the openings on a CNC)
#6 stick Aluminum foil duct tape on the back of the overlay in #1

Workings:
The mask gives access to each keypad, in this case 8X8.
The Overlay with aluminum foil is matched up to the PCB so a push on a key will make an electrical connection on the traces for that keypad.
Since there is no tactile feedback, I used a sonalert to beep each time a key is pressed.

Edit:
You may want to consider cutting individual aluminum foils for each button, however, one solid strip works 100% for single button push detection.

2014-08-26_17-41-21.jpg

Root_1.pdf (32.5 KB)