The Poly Wallet - Slim, Pop-Up, Cascade Wallet

Update: on the 2-year anniversary of Poly Wallet I’ll be releasing a 2.0 version. I will link it here once published. A few of the notable updates:

- Strengthened the tension arm and rails.

- Fixed the slim version, dimensions are nearly identical but holds 5 cards.

- Designed a cash drawer and larger version to accommodate it and 7 cards, or more cash and 5 cards.

- Standard wallet fits 7 cards, or 2 cards and cash drawer.

- Snap indentions for future accessories.

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The Poly Wallet is a slick plastic wallet for your plastic. Holds 6-7 credit cards, or 4 credit cards and 1 key card. Slimmer version holds 4 credit cards.

Prototyped with a 0.4mm nozzle, 0.2mm layer height. Sliced with Cura, printed on an Ender 3.

UPDATE: I added a slimmer version designed to hold just 4 cards - total thickness around 9.5 mm (original is about 12 mm thick). Also shortened one of the rails on the base to match the other/prevent catching on the end. The 6- and 4-card base and covers are interchangeable - but you'll have to make sure you have the correct lever (original lever with original base, and 4-card lever with 4-card base). 

NOTE

• You only need to print 1 base, 1 cover, and 1 lever. See the OPERATION Lock and Return Variation sections for details on the differences in function between the covers. The images, including the gifs, show the “middle lock” cover.
   

• The images do not show the most up-to-date version, but are close. Printables has some exclusives to help me recoup some of my prototyping filament costs (15+ prototypes …). Please download, like, and share to help me out! 

• Get permission to sell: https://buy.stripe.com/cN26ssd2T3Od400eUV 

• Donations appreciated: https://buy.stripe.com/28o8AA8MDgAZ2VW6oo

ASSEMBLY

See gif and image.

1. Remove any support, raft or brim. 

2. Place lever onto base knob/pin.

3. Slide cover onto base so that the base rails enter the cover track.

4. Slide cover until lever knob/pin enters cover track.

5. Place cards into wallet. 

   1. If you had any annealing on the first layer between the stopper arm and the base, you will need to separate them when you first put cards in. Carefully push your cards in, with some force.

6. If you need to remove the cover, remove the cards and tip the wallet on its left side. From the starting position, slide the cover up. If the lever doesn’t fall into the entrance/exit track, push it down with your finger. Then slide the cover all the way off. 

OPERATION

Stopper

• There is a small arm on the upper right corner of the base that prevents cards from falling out, and applies some tension when sliding out cards.

• Note: If you slide the cards out into a cascade AND tip the wallet upside down, the stopper will probably not prevent the cards from falling out.

Slider

• As you slide the cover up, the track forces the lever up - cascading the cards outward.

Cover Variations

Middle Lock Cover

• Lock: When you return the cover to a position in the middle of its track, it will lock the cards in the cascade position and prevent them from falling back into the wallet.

• Return: To return the cards, return the cover to its starting position and press the cards down.

Lower Lock Cover

• Lock: When you return the cover to its starting (lower) position, it will lock the cards in the cascade position and prevent them from falling back into the wallet.

• Return: To return the cards, slide the cover to its fully-extended position, then press the cards and cover down.

PRINTER SETTINGS

Layer Height

• 0.2 mm

Base

• Adhesion: Normal settings (unless elephant's foot removes bottom edge chamfer)

• Infill: Recommend 100%

• Supports: Original - no; Finger loop - yes

Cover

• Adhesion: Normal settings (unless elephant's foot removes bottom edge chamfer)

• Infill: Doesn't matter

• Supports: Recommend normal supports

Lever

• Adhesion: Normal settings.

  • Note: If you get elephant's foot, I recommend using a raft or adjusting other settings. It's very important that there is no elephant's foot on the lever.

• Infill: Recommend 100%

• Supports: Cascade - no; Split - yes