This is an instructable on how to make Laser Cut USB flash drive cover. It was cut out on an Epilog Zing Laser Cutter and designed with rhinoceros 3d. It was cut out of door skin and takes around 45 minutes to design and cut. The blank flash drive that I had came out to dimensions that were easy to design to..
Below at the bottom is the 3dm file. I know how it goes when your in a hurry and you just need the file, so here it is.
Step 1: Measure the Size of the Flashdrive
Measure the flash drive carefully with a good ruler or pair of calipers. Since the thickness of the door skin is 0.11". You will need to add 0.22" to width of the bottom and top pieces. Then add 0.11" to the length of the bottom and top pieces.
Step 2: Start Designing in CAD
Make surfaces of the sides of the bottom and top as determined in step one. Then repeat step 1 with the height and create surfaces for both sides back.
Step 3: Start Cutting the Surfaces So They Can Mesh
Make notches like in the photos above that will fit together for ease of assembly.
Step 4: Cut Them Out
Upload files into your laser cutter and let it do is job.
Step 5: Assembly
Glue the pieces together and add flash drive for completion.