ZSA Voyager rigid travel case

Description

This is a rigid travel case designed for the ZSA Voyager keyboard. Magnets secure the keyboard inside the case and also serve as the locking mechanism. The case’s hinge is formed from M4 screws and heat-set inserts.

A key design goal was pack-away speed. I move the Voyager between home and work every day and often travel with it. The case accommodates the keyboard with its magnetic feet still attached, so they do not have to be removed. Magnets snap everything quickly into place, and cut-outs let you stow the keyboard with the cables still connected - handy for short moves.

Parts list

• 8 × Neodymium disk magnets Ø8 mm × 3 mm
• 2 x Neodymium disk magnets Ø20 mm × 5 mm
• 2 × Heat-set inserts M4 × 5 × 8 mm
• 2 × M4 x 30 mm Socket Cap Screw (or similar)

Printing

• Material: I used PLA+ because that's all I have
• Layer height: 0.2 mm
• Perimeters/wall loops:  6 for strength - particularly around the interference fit magnets
• Supports: None

Assembly

• The magnets are a tight interference fit, so no adhesive is required. I drove them in with a pin punch and hammer. Remember to check polarity before whacking them in!
• Heat-set inserts go into the hinge on the left-hand case part (see attached images), and the hinge is fastened with M4 screws.
• I’ve offset the hinge’s centreline slightly inboard of the case’s mating surfaces; this compensates for any warpage and helps the opposite ends of the case close flush.

Let me know if you have any feedback.