How to build HP-41C custom overlays?

[pascal_meheut]

Hi,
I'm building my own overlays. First I design them using this excellent site I found here:
http://hp.meshuggeneh.net

Then I edit the SVG file and print it with my inkjet printer on some relatively thick photo paper.
I cut it with a laser cutter, varnish it and eventually glue it to another piece of paper to solidify it.

Is there a better way?

[pascal_meheut]

(08-01-2022 08:52 PM)blackjetrock Wrote:  I had a go with various ways here:
https://www.youtube.com/watch?v=ytt4MLXuYUU&t=178s

Thanks.
Mine look like this but they are too thick. I'm trying to find some plastic or vinyl I can print on before cutting it.
Something made of the same material as the original overlays.

[Didier Lachieze]

(08-01-2022 09:46 PM)pascal_meheut Wrote:  Mine look like this but they are too thick. I'm trying to find some plastic or vinyl I can print on before cutting it.

Very nicely done ! I’m impressed by the quality of the holes for the keys. Which laser cutter do you use?

[pascal_meheut]

(08-01-2022 10:03 PM)Didier Lachieze Wrote:  Very nicely done ! I’m impressed by the quality of the holes for the keys. Which laser cutter do you use?

Neje 3 Plus with their 12W plus laser head.
I cut slowly with 40% of the power and make 3 pass. The cutting is even better than what you see because I stupidly glued the photo paper to another more rigid paper.
So it is too thick.

I'm having a hard time finding some PVC sheets with the right size (A4 or paper), inkjet printable, not adhesive and around 0.3mm thick.
I found some but minimum order is 1000 pieces so I'll pass.

[rprosperi]

I'm not sure if this is possible/applicable to any of the printing / construction techniques you guys are exploring, but keep in mind that 2-sided overlays can make it much easier to carry multiple overlays, mounted right in the keyboard.

To do so, you have to make 2 small adjustments to the key hole sizes in the template design.

#1 Remove the vertical post between the 2 rightmost key holes in the 4th row (between the "RTN" and "Exit" keys in the example in the photo) creating a 2nd double wide hole on the 'other' side.

#2 All the key holes in rows 5-8 need to made slightly wider as the numeric keys are wider than the operator keys and when flipped, will not fit right unless slightly widened.

#2 is easier to see than explain, just flip over an existing overlay and you'll see what I didn't explain well.

This clever technique is not new and goes back to about 1980, for overlays made by Jake Schwartz and others in PPC, who pioneered paper overlays with hand-written labels. I still have a stack of them and and happy to send a sample if that would help, but I suspect just the above comments are all you guys need.

Good luck and please continue to share your results as they improve, and also if you would be willing to make some for other members (at a reasonable cost, no one should expect something like this for free).

[MeindertKuipers]

I had really good results with a 2nd hand Silhouette paper cutter. This allows you to print first (on photo paper for example) and then cut, as the printing contains the alignment marks for the cutter. Even overlays for the DM41X are possible.

[pascal_meheut]

Thanks for the answers. Here is the final result using Epson Semi-Gloss photo paper and Sennelier varnish.
It is not as rigid as I would like but it's ok and I can always build more.

I'm afraid that after the holidays, I will not have time to build more for forum members.

[JoJo1973]

(08-01-2022 03:53 PM)pascal_meheut Wrote:  Hi,
I'm building my own overlays. First I design them using this excellent site I found here:
http://hp.meshuggeneh.net

Then I edit the SVG file and print it with my inkjet printer on some relatively thick photo paper.
I cut it with a laser cutter, varnish it and eventually glue it to another piece of paper to solidify it.

Is there a better way?

Wow, impressive! I'd like to see this for other overlayable HP calcs...

[pascal_meheut]

(08-03-2022 09:47 AM)JoJo1973 Wrote:  Wow, impressive! I'd like to see this for other overlayable HP calcs...

Such as?

[Massimo Gnerucci]

(08-03-2022 11:22 AM)pascal_meheut Wrote:  

(08-03-2022 09:47 AM)JoJo1973 Wrote:  Wow, impressive! I'd like to see this for other overlayable HP calcs...

Such as?

71, 75, 48?

[pascal_meheut]

(08-03-2022 01:35 PM)Massimo Gnerucci Wrote:  71, 75, 48?

It is possible of course. One would need the image of the overlay and ideally the same without any label in svg format.

[Allen]

(08-01-2022 03:53 PM)pascal_meheut Wrote:  Is there a better way?

Some years ago ~2008? I hired a company to make a professional autocad file of the overlay and produce some stainless steel laser cut overlays. Since the global demand is much smaller now than back then, any scale production is inadvisable.

The DXF file is attached. No warranty expressed or implied whatsoever.

for 41c_Overlay_494.DXF
md5sum 9db039e4e0c270f613a307b331401f7f
sha256sum 80f83fd00b4f13181294337dea8ee1ab1c3901b34566670223d8e383be9a3e4d
(remove the pdf extension and uncompress)

Back in in 1985, (35 B.C.) J&D Manufacturing in Menlo Park, CA made a cleverly-named 24 pack of tear-off paper overlays called "Hangovers". I have some in my collection. (Should be listed in any Educalc Catalog from 1986-1987).

[Massimo Gnerucci]

(08-06-2022 03:12 PM)Allen Wrote:  Back in in 1985, (35 B.C.) J&D Manufacturing in Menlo Park, CA made a cleverly-named 24 pack of tear-off paper overlays called "Hangovers". I have some in my collection. (Should be listed in any Educalc Catalog from 1986-1987).

I have one pack of those!

[pascal_meheut]

The same in grey/yellow. I find it more readable. The color is less white than the one in the picture, closer to the original plastic overlays.

[Jake Schwartz]

(08-06-2022 03:12 PM)Allen Wrote:  

(08-01-2022 03:53 PM)pascal_meheut Wrote:  Is there a better way?

Some years ago ~2008? I hired a company to make a professional autocad file of the overlay and produce some stainless steel laser cut overlays. Since the global demand is much smaller now than back then, any scale production is inadvisable.

The DXF file is attached. No warranty expressed or implied whatsoever.

for 41c_Overlay_494.DXF
md5sum 9db039e4e0c270f613a307b331401f7f
sha256sum 80f83fd00b4f13181294337dea8ee1ab1c3901b34566670223d8e383be9a3e4d
(remove the pdf extension and uncompress)

Back in in 1985, (35 B.C.) J&D Manufacturing in Menlo Park, CA made a cleverly-named 24 pack of tear-off paper overlays called "Hangovers". I have some in my collection. (Should be listed in any Educalc Catalog from 1986-1987).

They appeared in EduCALC catalogs 30 (1986) through 44 (1989).
Jake