SKYWAY 96 — Custom Parametric Case (96% Hotswap)

A low-profile tray case for the SKYWAY 96 (96% /

Melody96-footprint) keyboard PCB, designed parametrically in

CadQuery and fitted to the board's exact outline, USB-C position,

and mounting holes — measured straight from the gerbers, not

eyeballed.

The PCB is held three ways for a rock-solid, no-flex feel: a

continuous perimeter support ledge, 15 M2 standoff posts (at the

board's real mount holes + edge notches), and a thin top clamp

lip. Ledge and posts are coplanar so the board beds flat and

can't rock or bounce when you bottom out keys. M2 heat-set

inserts recommended; self-tapping option included in the source.

Print it one-piece if you have a 350 mm+ bed, or as two

lap-dovetailed left/right halves that fit any 220 mm bed and glue

together at the seam (the dovetails self-align the bottom while

the glue sets). Optional 6° tilt feet slide into dovetail

channels in the underside for a proper typing angle.

Everything is parametric — wall thickness, post style, tilt

angle, USB position, even optional bezel/accent-stripe flair are

all toggles in skyway_case.py. Source, STLs, and a printability

pre-flight script are on GitHub.

Print Settings

- Material: PLA or PETG (PETG in an enclosure for the long parts)

- Layer height: 0.2 mm

- Walls: 3–4

- Infill: 15% gyroid

- Supports: none (all overhangs self-bridge)

- Adhesion: brim (long flat parts are warp-prone)

- Tip: enable ~0.15 mm first-layer/elephant-foot compensation for

a clean dovetail fit

- Feet: print ×2, on the sloped face

Post-Printing / Assembly

1. Heat-set 15× M2 inserts into the posts

2. (split) seat right half down onto left, glue the seam faces

3. Drop PCB in, screw down with M2 into the posts

4. (optional) slide a tilt foot into each bottom channel

Credits: Designed for the SKYWAY 96 open-source PCB. Built with

CadQuery (OpenCASCADE).