On 12/08/2012 08:31 AM, Erik Friesen wrote:

> Really the right way to do this would be to get a silicon keypad made, but
> for a one off project that is unworkable.

It sounds like you've already gone through a lot of trouble on this, 
which is typical for a one off project.  For all of your effort, you may 
be able to make a silicone rubber keypad overlay.

Have you seen the Jog It! control pendant on KickStarter?  It has a 
prototype silicone keypad.  Apparently his handmade prototype yellowed a 
bit after a year, but it's still very workable.  Or, you could keep the 
mold and cast another silicone overlay if the yellowing bothered you.

http://www.kickstarter.com/projects/1651082654/jog-it-open-source-controller-pendant-for-emc2-and

Jerome seems like an approachable hacker who would probably get you 
pointed in the right direction on casting silicone rubber.

Google also seems to know a lot about this topic.  You could probably 
find a material that didn't yellow.

https://www.google.com/search?q=how+to+cast+silicone+rubber




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