Remix of https://www.thingiverse.com/thing:4268067 which is not currently available on Printables. Modified to hold a Teensy 4.1, two spare microSD cards, and with an added label recess that can be revealed by prying off the front plate . This was designed with a Dirtywave M8 Headless installation in mind. See:
If you find the M8 as inspiring as I do please be inspired to support Trash80, and the M8's continued development, on Patreon.
Overview
A case in the shape of a Game Boy cartridge for the Teensy 4.1:
Cutout for the Micro-USB connector
Cutout to access the MicroSD card
Flexure button built into case to enable pressing of the programming button on the Teensy
Cutout + flexure arm to insert and remove from the case up to two extra microSD cards
Passive exhaust cutout for the microcontroller
Printing
The case in the photos is printed at 0.1mm resolution. I have not tried it at a coarser granularity, and due to some of the details involved I do not think it would successfully print at lower resolutions.
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The Teensy gets very hot during operation. So hot, in fact, that PLA warps and is unusable. As such, you must use a more temperature-resistant material. I have only tested with PETG, which works, but other materials with equal or greater thermal resistance should suffice.
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That being said, I have found that PETG has the appropriate amount of flexibility for the arm that holds the spare microSD cards in place. Other materials may be too rigid and brittle.
The two halves should be printed as-is. If you intend to affix a label to the cartridge, you will need to also print the label insert.
Assembly
Case
There is a print-in-place support foot that is attached to the tab/lever on the flexure arm that holds the additional microSD cards is place. This should be extremely easy to break off.
The Teensy should be inserted from above, and at an angle, into the back shell, micro-USB-connector-first.
Once the Micro-USB connector is inside the cutout in the wall of the shell, the Teensy should be able to be snapped down into place.
Similarly, the front shell has two tabs at the top, and should be inserted from above, and at an angle, into the recesses in the top of the back shell, and then snapped down into place.
Label Preparation
If you wish to apply a label to the case, some assembly is required:
Using fine tweezers or a similarly thin but strong instrument, begin prying around the plate sitting in the label recess. Work your way around the edge and then spiral inwards. You can additionally try running your tweezers up the channels between the ribs holding the plate to the case front.
Once the plate is removed, apply adhesive of your choice (I used CA glue) to the back of the label insert, making sure to evenly cover the entire surface, but especially the edges and corners. Place the label insert into the label recess of the case front. You can put the just-removed plate on top of the insert, allowing you to stack a heavy object on top to apply pressure while the glue dries. You should now have a smooth, flat surface to which a label can be applied.
euphemism
