The four types of Jazz.

@ancientjames Do you have some kind of tooling to make the silicon part of the molds? They need to be very accurate for the 0.1mm on top of the screen and you made a good number of bricks which look well done... and if you have made a mold do you test it using a some sort of dummy or the risky way on a actual assambly?

Sorry to ask so much but I realy like that project and realy hpope that you can make some sort of kit or publish all nessesary to build one if anyone has also the skills...

@hsdd For a previous project I had been putting thin plastic shims between simple silicone mould halves to fine tune the internal dimensions, but it wasn't very repeatable, and I had to keep replacing the shims as they got coated in resin. Keeping the silicone in rigid 3D printed shells fixed the repeatability, and was also intended to make it easier to build up or grind down the separation points. (As it turned out, by the time I turned to this approach I had the dimensions correct.)
@hsdd I went through a lot of iterations to get to this point, but it now produces good results reliably (albeit still labour intensive). I used real assemblies throughout. There weren't many outright failures, but the early attempts are generally quite poor quality.

@ancientjames Thank you very much for thanking time to answer my questions...

I had hoped you have some kind of 3D printed Part which holds the "original" brick in the right position in relation to the 3D printed frame of the molds... So it is easyer to make the silicon parts precisely... You mentioned in a orher thread that the hardest part comes after the assembly of the electrics and I think you're completely right...
Learning to prepare the resin etc is a chalange I would except for myself but I have no clue how to construct the mold... And including it in a kit seems too much production expense for you (I think).

Do you still working on that project (from time to time) or did you move on to new more interesting things?

Still hope to get the chance to build one some day... because I was blown away the first time I saw a article about the first version a while ago... and building it myself would be a delightful challenge...

@hsdd I don't have a video of the moulds being made, but here's a picture I took of one before pouring the silicone. The donor brick clips to a 3D printed lid.

I'm still working on how to make these bricks available, but if there does end up being a kit / electronics-only version, I'll share the STL files and instructions for people who want to do the whole process. (They're not much use without the specific PCB assembly they go with)

@ancientjames thanks again for answering and the time you spend into the project.

The tooling for making the bottom part of the mold (top-part of the resulting brick) looks very solid and I think the top part has some clever tooling too...

The Keyboard project is cool too... You're a very (multi) talented person... I whish I had so much knowledge in electrics etc ;)