Easy Access Card Wallet (6 cards)

The popup card wallets are really cool.  So I took the idea and added some of my own improvements, to create a even better wallet.  It's also very attractive how the pattern surface catches the light.

The wallets shown in picture were printed on the single extruder Prusa Mk3S+, with manual color change.

Easy identify and access each card.  Existing card wallets have the very little of each card exposed, which makes it hard to identify each card (especially black card is the current trend).  The small amount of each card expose also make it difficult to grip and pull out the required card.

I solve the problem by offsetting the cards both on the top and bottom.  Now each cards has doubled the exposed surface, as compared to existing six card popups.

Handling of embossed cards.  The standard card thickness is 0.8mm.  Cards with embossed text increase the height by another 0.5mm.  Existing wallet just assumed a common card height of 1.2mm, so you need to to stack your cards in a specific order to get the wallet to work properly.

I solve this issue by having the top and bottom position to fit both embossed and non-embossed cards.  As shown in the picture, I have indented the inside of the top and bottom plate to fit any embossed text.

Clean Surface to add graphics.  I also want the wallet to have a clean surface, so that I can add graphic to individualize the wallet.

I've included a few extra patterns for the wallet.  You are welcome to create your own artwork (dimension is 60.375 x 96.125 mm with 3mm radius).  Just remember to share your graphics with everyone in the community.

Printing and Assembly Notes

In the slicer, add the pattern you want to the print bed, then add the top/bottom plate on top.

I reduced the extruder height in the First Layer Calibration, so the filament get squashed against the print bed and you don't see the filament separation; but still allow the printing pattern to catch the light. 

Print top+bottom plate printed in 0.2mm layer height and the lever with 0.1 layer height.  The lever has been split, to improve print quality.  Optionally, you can add a piece of filament to the small holes in the lever, to ensure that the parts line up perfectly.

Add a small bit of foam to the indent in the inside wall.  This is to grip the card to stop them from falling out.  I cut about 2mm thick foam for this, but you will need to try to see how tight the movement is.

You'll need to remove blobs and raised prints from the model.  Every printer have different tolerances; and every filament behaves differently (even for different color of the same filament from the same manufacturer).  You'll need to fine tune the movement before putting it together.  And for materials with larger shrinkage like ABS, you will need to scale up the print by a small amount.

Instruction for manual color change can be found at https://forum.prusa3d.com/forum/prusaslicer/manual-multicolor/ and https://www.youtube.com/watch?v=KV2AjyowXX4.

I noticed a strange spirit shape on a few layers when printing the top plate using the Japanese Asanoha pattern.  Didn't happen on the bottom plate, even though the top plate is a copy of the bottom without the walls.  Didn't happen to other pattern either.  Don't know what is causing it.  But, I now have a Japanese spirit in my wallet!

You can check out my other prints at https://www.printables.com/social/76585-highrise-workshop/models.  And don't forget to click the “Like” button.