As a pilot our library is renting out Micro:bitsklooikoffers, which I think is really cool! The Klooikoffers are supplied by Conrad, but they come in a cardboard box. To make the Klooikoffers suitable to be rented out, we have made some changes :) And since koffer means suitcase, we wanted it to look like a suitcase.
Step 1: Find/buy a Case That Suits Your Needs
Step 2: Print, Cut, Laminate and Prepare the Paperbits
We've decided to print the paperbits (scaled 108% when printed on A4), cut them, laminate them and add the copper tape to the laminated versions. Now people don't have to print and cut the paperbits themselves, but more important: it will save a lot of (expensive) copper tape.
Step 3: Lasercut the Inlay
Since we made 20 cases, we bought 3 layers of foam (2cm thick) (sourced locally as well) that were already cut to the right size, so we only had to engrave text and cut the shaped holes.
Layer 1 only has text for the 2nd layer (made with Hershey text in Inkscape for the nicest result)
Layer 2 has 2 big holes for the paperbits and the wires and has text for the 3rd layer
Layer 3 has small holes for the components
The smallest components (leds, piezo and ldr) are pinned into the foam to make their storage easier.
Glue the layers on top of each other (i used spray on glue) and add a 2 small strips of foam on the left side of the booklet to make sure the booklet remains on its place.