From the Loftsmith Workshop

Pocket cyberdeck case for Pimoroni Badgeware and CardKB

A clamshell pocket cyberdeck: a Pimoroni Badgeware badge (84 x 76 mm) snaps into the lid and an M5Stack CardKB keyboard locks into the base. Two M3 bolts with nyloc nuts make an adjustable friction hinge, and the lid leans back onto a printed stop at 110° (95 to 120° on the slider). Four PETG hooks hold the badge, with a USB-C window on the left and a back window for the Qw/ST lead. The CardKB tucks under two front lips and is locked by a screwed bay cover that also hides the Grove lead. Sliders set badge thickness (12 to 22 mm), fit clearance (0.15 to 0.6 mm), stop angle and the depth of the

3 parts · 59 g · 93 × 137 × 90 mm

by Loftsmith Workshop

Pocket cyberdeck case for Pimoroni Badgeware and CardKB
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No adjustable sizes

Ask for the sizes you want to tweak, e.g. “make the width adjustable”.

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Parts

  • base · PETG · Flat, bottom down as modelled; hinge barrels and rear fins stand on the bed. No supports.

    93.4 x 101.7 x 14.3 mm. About 27 g and 40 min at the page's 2 walls / 15% (more at the recommended 3 walls). Holds the CardKB pocket, the Grove lead bay, two M3 nyloc pockets and the stop heels.

  • bay cover · PETG · Top face down on the bed, tongue and screw pad pointing up. No supports.

    74 x 24.3 x 5.5 mm. About 3 g and 9 min at 2 walls / 15%. Locks the CardKB's back edge and hides the Grove lead.

  • lid · PETG · Outer back face (the face with the window) on the bed, badge tray opening up. No supports.

    93.4 x 90.7 x 28.3 mm at the default 20 mm badge thickness. About 28 g and 43 min at 2 walls / 15%. PETG rather than PLA for the four snap hooks: 2.8 % peak strain at the default 0.3 mm fit (2.4 % at 0.15 mm, 3.4 % at 0.6 mm); PETG allows 5 %.

Print settings

Layer height
0.2 mm
Walls
3 walls (stronger hinge barrels and snap hooks)
Infill
15%
Supports
None
Notes
PETG. At the recommended 3 walls / 15% infill all three parts take about 83 g and 2 h 8 min. At the page's default 2 walls / 15% it is about 61 g and 1 h 35 min. All three fit one Bambu A1 plate together. On a 180 mm A1 mini bed the base (93 x 102 mm) and lid (93 x 91 mm) go on separate plates.

Hardware

  • 2 × M3 x 20 socket head screw · Hinge pins, one per side, inserted from the outside of each hinge.
  • 2 × M3 nyloc nut · Pressed into the hex pocket on the inner face of each inner base barrel; their tightness sets the hinge friction.
  • M3 x 8 countersunk screw · Holds the bay cover; threads straight into the printed boss.
  • M5Stack CardKB keyboard · 88 x 54 x 5 mm, from M5Stack's product documentation.
  • Pimoroni Badgeware badge (Badger, Tufty or Blinky) in its case · 84 x 76 mm; set the Badge thickness slider to your badge.
  • Grove to Qw/ST (4-pin JST-SH) lead · Connects the CardKB to the badge; not checked for electrical compatibility.

Assembly

  1. Press an M3 nyloc nut into the hex pocket on the inner face of each inner hinge barrel of the base.
  2. Set the lid's two barrels between the base barrel pairs. Push an M3 x 20 screw in from the outside of each hinge and thread it into its nyloc. Tighten until the lid stays where you leave it, then a little more if it still drops.
  3. Plug the Grove lead into the CardKB. Lower the keyboard into its pocket pushed about 1.6 mm toward the hinge, then slide it forward under the two front lips.
  4. Lay the lead through the notch behind the keyboard, across the Grove lead bay and out through the notch in the middle of the back wall.
  5. Drop the bay cover in with its tongue behind the keyboard and fix it with the M3 x 8 countersunk screw.
  6. Press the badge into the lid, screen facing out and USB-C toward the left-hand window, until all four hooks click over its front edge.
  7. Take the lead round the middle of the hinge, between the two barrel pairs, and over the lid's back into the back window to the badge's Qw/ST socket.
  8. To take the badge out, push it from behind through the back window while easing one hook outward.

Good to know

  • Not print-in-place: the hinge is two bolted barrels. Friction depends on how far you tighten the nylocs; the holding estimate assumes a friction coefficient of 0.3 and has not been measured.
  • The badge size (84 x 76 mm), USB-C on the left edge and Qw/ST on the back come from Pimoroni's documentation. The USB-C window is 18 mm long and assumes the port sits near the middle of that edge; check your badge before printing.
  • The CardKB size (88 x 54 x 5 mm) comes from M5Stack's product documentation. There is no slider for it, so measure yours: a larger board will not fit the pocket.
  • The badge hooks and the CardKB lips each reach 1.0 mm over the edges. Make sure your badge case and keyboard have a border that wide and no keys under it.
  • The CardKB's Grove socket is assumed to be on its back edge, toward the right-hand side. The route is planned for that position.
  • The tipping check assumes a 50 g badge. A much heavier badge at the 120° stop may tip back on a table.
  • The snap hook strain, stability and friction figures are engine estimates, not tests. Print one lid and check the badge clicks in before printing a batch. Not designed to survive drops.
  • Electrical compatibility between the CardKB and your badge's Qw/ST port is not checked by this design.
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