Ribcage - Skelett 40 case - KAY-004

This is my second case design, a case for the Skelett 40 by Novelkeys. The design is 100% 3d printed with no screws or additional fasteners. The case has options for either full WK bottom row or HHKB blockers. The case in the photos is printed with PLA but other types of filament should work as well.

Grab the Skelett 40 PCB here: https://novelkeys.com/products/skelett-40-keyboard-kit

UPDATE 2026-04-26: added a version that works with the original fr4 plate, in case you have one already soldered together. This is untested and quite frankly needs some more tuning, let me know if you have any feedback. (I lost my fr4 plate)

Requirements:

• At least 250mm in one axis for the print area.

• Dimensional tolerance dialed in. I designed with .02mm clearance and everything fits pretty tight when printed on my Sovol SV08.

Print instructions:

• I recommend 4 walls/perimeters and .2 layer height for each part. Infill shouldn't matter much, I used 20% triangle infill.

• Print the bottom case with the bottom touching the build plate. Print the top case with the top facing the build plate. There should be no supports required. There will be 45 degree overhangs.

• Print 8 clips, laying sideways onto the build plate. This maximizes the surface area touching the plate and maximizes the strength of the parts. I would print this in 100% infill or use enough perimeters to fill out the clips.

• I used “Precise Wall” and “Precise Z-height” in OrcaSlicer, i'm not sure how necessary this is. I designed each part for .2 layer height.

• Print the foot with the bottom touching the build plate.

Build instructions:

1. Test your PCB in VIA to make sure everything works.

2. Install stabilizers to the PCB if desired.

3. Install switches to the plate, mate to the PCB, and solder in place.

4. There are 4 small holes on the long edges of the bottom and top case. They should be 1.75mm to accept short pieces of cut filament. If the holes are undersized, drill them to size.

5. Cut 4 pieces of filament to about 5-7mm long (I used PETG filament for this, but PLA should work). Press fit them into holes in either the top or bottom case. They will be used to align the case halves together later.

6. Insert the assembled plate and PCB into the bottom case. The pegs on the plate should nest into the rounded cuts on the bottom case. If it's your first installation this may require a bit of force to get it initially seated.

7. Seat the top case onto the bottom case. The pins you installed earlier will help with alignment and keeping the long sides together.

8. Slide 4 clips on to each of the short sides. They should be a pretty snug fit into the grooves on each side of the top and bottom case.

Video build will be published once I edit down the VOD of my personal build. Feel free to reach out if you have any questions.