Extreme Business Cards

Step 11 Encapsulating it

This step shows you how to make enclosures for electronic gadgets using PVC cards - using solvent cement to glue them together - this could be a separate instructable just by itself. I have now used this technique for other things like a credit card torch, which was wired using stick-on copper tape (perfect project for kids), and even a bugging device. They look professional, even without a graphic overlay, are easy to build, and super cheap as well. You can make them any thickness using multiple spacer cards between the front and back. For this project we need two spacer cards as they are around 1/32" (0.8mm) each. For thicker projects you can cut strips of "PVC foam" and use this as a spacer instead.

Place the circuit board on the card, and draw around with an OHP marker or similar. Then cut out the inside with a pair of small, sharp scissors. Doesn't really matter if you make a cut in from the side, as this will be hidden anyway, but if you are a little retentive like me, you can drill a hole in the middle first, and then cut out the inside without making a cut to the edge. The dotted line shows where you need to cut slightly inside the line to form a lip where you can glue the piezo disk.