E80-1800 VS kad

Depends a lot. If you want it fully assembled, you have to go to larger fab houses like PCBway, and spend a few hundred bucks on a 5pc batch. If you can hand-solder some parts (in this case, the Bluetooth module and the USB connector) and design the rest around jlcpcbs libraries, you can get away with 20-30USD per unit (MOQ of 5) plus shipping/customs. Then add another 10USD for the bluetooth module and USB connector.

A simpler wired design like my E80-1800 (https://github.com/ebastler/E80-1800) can be completely assembled by jlc for ~30ish USD per unit.

Oddly enough, small-batch prototyping at jlc can be cheaper than medium sized (50-150 pc) runs at other fabs.

Hope this doesn't sound like an ad, I've compared a lot of prices and nobody came close to jlcpcb, but With their limitations (limited stock, limited finish/color choices, frequently chnaging stocks and component prices) and sometimes far-from-ideal QC (some scratches can happen, in rare cases even missing components that were present in the BOM) they are not really my first choice for production runs. For prototypes or small unofficial-ish batches with a few friends though - god tier.

Some options include but are not limited to TKC1800 PCB, E80-1800 PCB, GH80-3000 or 3003 PCB.

As for switch hole sizes, I haven't designed anything myself but heard ppl use http://builder.swillkb.com/ to design their plates - it's some generator with size standards for switches and stabs.

Not 3d printing, but found this site which can generate files for laser cutting http://builder.swillkb.com/

In terms of workflow: I'm using a generated layout from Plate & Case Builder - swillkb after pasting in the raw data from http://www.keyboard-layout-editor.com/ : if there's a better workflow out there im all ears and open to trying anything new.

Use SwillKB to create layer design files

I design my own key layout and copy paste the raw json file to this site to generate the case and the plates. http://builder.swillkb.com

The only thing is, it's hard to do a plateless design with handwiring - but not many customs are plateless, anyway. You'll need to get a plate cut, but that workflow can be quite streamlined using a tool like Swillkb's builder.

I used this incredible tool to generate the top and bottom .svg files for the switch portion of the plate and a vector graphics editor to make the silly screen bump on the top right. The cost for the plates on this one was around 180USD after shipping but they charge by area so I was at a distinct disadvantage. I wish you luck on your keeb! This project was very fulfilling once all the bugs got hammered out, I hope yours is as well.

If you can't find a plate file, make a QAZ layout with KLE, import it to this plate generator to make a plate file. The thing is, the generated plate file will be without mounting point or holes. If you want more control, use this one, it's more complicated but with more options.

I just swiped it off of here. seeing as it's a custom board and all hahaha.