keycap creation process
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1. modeling
each design is 3d modeled with meticulous attention to every detail using autodesk maya. this step may take from 1-2 weeks depending on complexity of the design.
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2. printing
the master sculpt is printed using a resin printer. from here, we decide what tweaks need to be made. a design may be printed up to 10 times before it's perfect.
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3. mold making
using the master print, dozens of molds are made using platinum silicone cured inside a pressure pot.
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4. multishot casting
this is the most time consuming step of the process! urethane resin is dyed and applied inside the mold using a fine tool. each color of resin is its own separate layer. each resin layer takes 1 hour to cure inside a pressure pot.
a batch of 15-20 keycaps may take up to 5 days to cast.
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5. demolding
after casting, each mold is opened to reveal an adorable artisan keycap. at this stage we roughly inspect the keycaps to categorize into a or b grades.
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6. sanding
using varying grits of sandpaper, each keycap undergoes 2-3 rounds of manual sanding to ensure all edges/ undersides are smooth and even.
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7. quality check
as orders arrive at lbc hq, each keycap is carefully inspected and polished before being carefully packaged.
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8. drop off
keycaps are dropped off at the post office. we can't wait for them to arrive at their new homes!