Introduction: Fix a Damaged USB Memory Stick Case

About: I have a laser cutting business where I make bespoke laser cut art. I also work in schools as a Design and Technology Technician

If you’re like me, you use USB memory sticks all the time! I throw them into my laptop bag when I’m on the move. An unfortunate side effect is that they can get bashed around a lot and occasionally their cases can get damaged. In this Instructable, I will show you how to make and replace a USB memory stick case with a more durable, natural and attractive enclosure - made from oak!


  • Scrap/offcuts of wood (I used Oak)
  • Hot glue
  • Wood glue
  • Masking tape

Step 1: Step One:

Start by backing up the data from the memory stick on to your computer/laptop. This is important in case you accidently damage the circuitry during this process. Once you’ve backed up, carefully dismantle your memory stick. Take care when doing this, you don’t want to damage the memory stick or injure yourself. Once the circuitry is removed, use masking tape to protect it whilst it is without a case.

Step 2: Step Two:

Using calipers or a ruler, measure the dimensions of your ‘naked’ memory stick and cut your wood accordingly. I measured the thickness of mine (which was approximately 3mm) and cut three pieces of oak to this thickness. One to fit around the memory stick and two to sandwich the circuitry between.

Step 3: Step Three:

Mark out your dimensions and then cut your wood. You can do this with a hand saw or bandsaw etc. Once done, give each piece a light sand.

Step 4: Step Four:

The next step is to glue the bottom piece to the middle section and then clamp the pieces together. When it is dry, add your memory stick into the slot and cover with hot glue. Once this is dry, you can finally add the top piece of wood and clamp it.

Step 5: Step Five:

Now that the memory stick is fully encased and all the glue has dried. Mask the exposed USB terminal to prevent damage. Cut any excess wood and then sand the entire case to achieve your desired finish and then seal with a wax or varnish of your choice.

Step 6: All Done!

There you have it! A unique and fully fixed USB memory stick! This process doesn’t just have to be for damaged USB memory sticks. Why not make a unique gift for someone. If you are fortunate enough to have access to a laser cutter, you can even personalise your memory stick.

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