I'm one of the founders, I exited after the acquisition and now work in VC.
It's absolutely possible, the custom EPD was $40USD, we used injection molder keys, and a delrin keyframe. The remaining components for the display timing controller and the keyboard controller were dollars each at scale (excluding the TCM chip which was relatively expensive).
The entire BOM cost of goods was far under $100, and was comparable to a Macbook butterfly switch keyboard module.
The entire design with Foxconn / it's customers was specifically for MOQ's of 300k units. We did beta units to 40+ countries.
The NRE for the display was also double your estimate and took around 9+ months to get finished + a few months of delays due to terrible yields on the first Mass produced units.
I'm one of the founders. The site crashed due to the traffic, we sold the technology, IP and some of the key talent joined Foxconn late last year; and scaled back our servers during the transition.
I'm a keyboard enthusiast, it started with an IMB model M and that's how the original prototypes started. The feedback regarding adopting Apple design and ergonomics was a reflection that our main strategic partner, investor, and eventually owner was Foxconn, and the customers we engaged with were B2B and set the spec.
For our Macbook projects, it was specifically a Butterfly switch spec we have to match in performance and design. I'd have loved to create a product aligned to what you're referring to, but strategically we have to achieve a MOQ of displays to be economically feasible, and our cooperation with Apple was easier to secure the 300k of displays required than trying to tackle the B2C premium keyboard consumer market.
I'm one of the founders, E Ink displays have their display drivers on their glass substrate, meaning you would have a border that on a single key display would be too significant. We went with one large display with only one driving board for the entirety of the keys. This greatly reduced the unit cost to have one large EPD than 80+ small ones.
I'm one of the founders, the first unit used a prototype EPD from E Ink Holdings, a custom display with around $500k in NRE was developed for a Macbook size keyboard module.
This single large display with a magnetic mechanism operating around the footprint meant the total unit cost in COGS was significantly lower than $100USD at scale.
The entire mechanism was only a few mm in height including the display. The travel and tactile profile was designed to a butterfly switch mechanism spec.
I'm one of the Founders at Sonder.
We found from our test units that uses can work up to 30% faster with dynamic keyboards and had strong responses particularly from developers.
The company, the intellectual property and some of the key talent was acquired by Foxconn, the current design is quite polished, as is the user interface.
In regards to the cost point, it's one large display is a magnet mechanism operating within the periphery. This greatly reduced the unit cost and complexity of the design so it was scalable and comparable in price to an existing laptop keyboard module (when supply chain costs and keyboard layout revenue factored in).
Sonder Design
Hiring in Sydney Australia, San Francisco and Shenzhen
Www.sonderdesign.com
We have partnered with he world’s largest largest manufacturer Foxconn to create smart laptop keyboards that show any languages or shortcuts to work faster whilst still being tactile.
We are recruiting talented engineers in software, firmware and hardware.
See www.sonderdesign.com/careers for more information.
I'm the founder of Sonder, an E Ink smart keyboard startup; I've written here previously about E Ink when we were published in WSJ regarding Apple.
E Ink is a brilliant display, but the process of manufacturing, cutting the TFT mask etc is expensive; only on mass volumes can displays costs become incredibly cheap (6" E Ink in a kindle is <$10 USD). It's the same for most displays OLED etc in small volumes are expensive; which is why the touchbar solution COGS is over $200 USD.
Therefore E Ink has a high MOQ of a few hundred thousand units, anything below that and you're priced at basically prototype costs which is why a 32" E Ink display is $2k.
Because it's a prototype, we went for existing displays and a 60% was the closest. Besides, you for your a 104 key keyboard and the price just doubled.
It's a patented mechanism, the profile is more similar to the older macbooks but audibly sounds a little like a mech; like a topre, not like cherry blues.
We wanted to create one standard that could be used for all different layouts. Due to accents used in many Asian and European layouts, and only a few Western European nations adopting ISO (UK et al) we went for a single row enter.
We did testing with users and it's a compromise but our intention is redefine the standard, having 2 dominant standards doesn't make sense, likewise with non ergonomic design and staggered keys.
The MOQ is 300k units; we're at economies of scale but it's still a new technology. You're right on the made in China, Suzhou, Shenzhen etc. Bingo also on the third point.
Thanks for the comment, you're very right; but these two were mass production units that still preserved much of what the earlier units great. We have a few earlier Apple alps kbs you mentioned, but I'll shoot the Model F to our slack channel.
Thanks for the comment, you're very right; but these two were mass production units that still preserved much of what the earlier units great. We have a few earlier Apple alps kbs you mentioned, but I'll shoot the Model F to our slack channel.
I work mostly on the electrical side but we do interact a lot with the software devs (I can code but only in C++), it's not gospel but I think the scope for the software is an open API.
The entire design with Foxconn / it's customers was specifically for MOQ's of 300k units. We did beta units to 40+ countries.
The NRE for the display was also double your estimate and took around 9+ months to get finished + a few months of delays due to terrible yields on the first Mass produced units.