Custom foam insert - Pelicase 0915 for SD cards

thingiverse

Here's a custom foam insert for the Pelicase 0915, designed specifically for SD cards. Originally, this case held six micro SD and twelve standard SD cards - you can see the removed original insert in the second photo. Now, I've been able to fit an impressive twelve standard SD cards along with eighteen micro SD cards. You could even take it a step further by making it hold twenty-four microSD cards if you replace the two original foam inserts with new ones. To create this custom insert, I used EVA foam in three layers, each 2mm thick. The bottom layer features no cuts but is shaped to match the inner case contour perfectly. The middle layer has micro SD card cutouts and a matching contour shape. The top layer boasts standard SD card cutouts along with a matching contour shape. A 3mm thickness for the standard SD cards layer would likely be an improvement, but unfortunately, I didn't have any on hand at the time. To bring this custom insert to life, I relied on my DIY laser engraver/cutter equipped with a powerful 2.5W laser diode. And there you have it!