ATTENTION! This is both Instructable AND a challenge. You can be one of five winners of $100 worth of 3D printing credit from the nice folks at 3Dcreationsystems.com. All you have to do is make your own 3D design for a custom flash drive case and share a picture of the design in a comment below.
If you don't know anything about designing in 3D, don't worry! A template for the flash drive is at tinkercad. All you need to do is create a new account (easy), duplicate the template (still easy), and modify it (way easier than it sounds). And if you want to use your own favorite CAD program and make your own case from scratch that's also fine.
OK then, let's get started.
Step 1: Measuring
Here we get a height and width of 4.54 mm and 12.26 mm. This isn't too far off of the USB standards so that's good. It also has a length of 39.11 mm. Since flash drives need at least 12 mm at the end to go into the USB port, that gives us the dimensions 27 mm x 12.25 mm x 4.5 mm. Numbers slightly rounded off there.
Step 2: Making the Template
In this picture, there is the void in the middle and the outer shape that is 4 mm thicker and taller than the inside shape. This gives us a quick open-ended box. Which is close to being done.
The last addition are two small (1 mm) hemispheres. These help to apply pressure to the flash drive to keep it in place.
You can see the resulting template here.
Step 3: Making a Slightly Fancier Template
You can see this template here.
Step 4: Modifying by Adding and Subtracting
You can see the ghost flash drive file here.
The other option is to just subtract a bunch of geometric shapes to form a pattern. Here I just created a series of long box shapes and cut them from the template.
You can see the diamond flash drive file here.
Step 5: Print!
With these in hand you can put your flash drive in. It should be snug enough on its own, but for some extra security put a bit of glue to keep it rock solid.