After the my cover broke off my Cruzer 512 MB USB drive, I decided to fashion my own case. I saw several ideas floating around on the internet such as cases made of Lego, pez dispensers, and and even a Barbie doll. I cast the USB stick in clear casting resin used to make paperweights out of scorpions or flowers. I picked it up at my local Hobby Store for about $15. It comes it two parts: the resin and the catalyst. If you're making a cast, test it out on some scrap bits and pieces to make sure your ratios are correct.
Check out http://www.tcnj.edu/~jones37/usb.html
Step 1: The Specimen
Very Stylish Duct tape case
Step 2: Open Case
Crck open / otherwise dismantle the case
Step 3: Molding Rig
This is a molding rig created with scrap pine wood and clamps. The pine was covered with clear packaging tape to prevent the resin from sticking to the wood.
Step 4: Resin
I obtained resin from my local hobby shop.
Step 5: Pour the Resin
The long part. The casting was done is several parts. Everything was done in about two days time.
Step 6: Done!
USB Stick in see-through glory.
Step 7: Lanyard
I drilled a small hole to fit the rope back on so I could still hang it on the lanyard that I got with it. A small bit of J-B Weld attached the rope back to the clip.
Step 8: Admire Your Work
This picture was taken after about a month of use. I don't think I got the ratio of catalyst to resin quite right. This caused the top surface to become mottled. Otherwise, there have been no problems as a result of the casting.
Check out http://www.tcnj.edu/~jones37/ for my other projects!