Custom PCBs for a RP2040 powered rectangle controller.
Modified version of https://github.com/Armastardo/OpenRectangle that decreases size of the PCB and changes button layout to accomodate.
Original Dimensions: 339.13mm x 141.22mm
Modified Dimensions: 282.7mm x 136.22mm
Case Dimensions: 296mm x 154.4mm (~11.65" x ~6.08")
(Thickness of the case varies based on thickness of acrylic layers)
Case Standoffs:
https://www.aliexpress.us/item/2251832708378430.html?gatewayAdapt=glo2usa4itemAdapt&_randl_shipto=US
Calculate the thickness of your case and order standoffs about 1mm shorter than the case.
Case Screws: https://www.amazon.com/dp/B0798227SK?psc=1&ref=ppx_yo2ov_dt_b_product_details
Any M2 screws will work, I got these because I wanted black ones that are flush with the case.
Acrylic:
There is a huge variety of colors and different designs of acrylic offered by these guys but they are a bit more expensive than other places. Also I had to pay about $17 for shipping so be sure to account for shipping costs in budget. If you order a 12 x 19 inch sheet from here you are able to cut 3 layers out of it.
If you are trying to make it as cheap as possible, I would recommend shopping around for clear acrylic because clear seemed to be the cheapest when I was looking. Here are a couple different thickness ones from amazon that I found:
1/8" For Top/Bottom Layers + PCB Layers on Aluminum Switchplate Design: https://www.amazon.com/dp/B09XR8NB28?psc=1&ref=ppx_yo2ov_dt_b_product_details
Acrylic Switchplate (.06"): https://www.amazon.com/dp/B09LTYDYKP?psc=1&ref=ppx_yo2ov_dt_b_product_details
PCB Layer/Hotswap Cutout Layer on Acylic Switchplate Design (.08"): https://www.amazon.com/dp/B09N3PN8PG?ref=ppx_yo2ov_dt_b_product_details&th=1
I recommend doing some searching on your own as there may be different options that are cheaper. 8" x 12" works the best for cutting 1 panel per sheet and for getting mroe than 1 panel per sheet you need multiples of 6.315" x 12". For example, 12" x 19" can get you 3 layers with very little margin of error or 12" x 21" would get you 3 layers way more comfortable although you are unlikely to find this size and would more commonly find 12" x 24"
3.5mm M1.6 PCB Standoffs:
https://www.ebay.com/itm/185215966272?var=692974532230
3mm M1.6 PCB Screws: