Re: I'm designing a Thumb Drive

For low volume or a one off:

Scavenge a case from a small-capacity unit. Lots of 8M, 16M 32M, 64M,
128M, 256M units that were sold and/or given away as convention freebies
floating around doing nothing much these days.

Chop off a chunk of a butane lighter (empty, pick up on side of road)
and use hot glue, silicone or epoxy to mount/encapsulate.

Use hot glue straight up to encapsulate, perhaps pulling a mold from one
you like the shape of with RTV silicone or plaster - or just get
artistic in your application of heat to achieve the shape you want with
no mold at all. Cut a pair of sides from a wooden tongue depressor and
make a hot-glue ice-cream sandwich around the board, as one approach.

Following a typical commercial design - Buy suitable metal tubing
(round) and squish to (oval) - then all you need is end plugs - again,
epoxy, silicone or hot glue should work in low volumes.

--
Cats, coffee, chocolate...vices to live by
.

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