Wooden Pendrive: Personalize your USB Flash Drive with This Simple Tutorial! 2026

Wooden Pendrive: Personalize your USB Flash Drive with This Simple Tutorial, all that is required is a small square of wood, I cut a slice from one of my blanks about 7mm thick, so you would end up with a small square of 55x55x7mm. I did many tests of many types of wood, but the one I took to show you was one made of olive wood. Below is a list of things you will need.

Materials:

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• Wood: You can use any type you want, I started with a blank and cut a slice, 55x55x7 mm.
• Router: A Dremel with a depth control accessory will also work
• Glue: Your favorite wood glue.
• Hot glue gun: will be used to secure the pen drive in the case
• Pen Drive: Cheap Pen drives are almost always made the same and can be purchased in bulk if necessary.

Step 1: Prepare your wood

I used a circular saw to cut slices from a blank, but a hand saw will work just as well. It is best to have a thickness between 6 and 7 mm. After you have your slice, it is recommended that you have a surface.

This can be done by hand with a planing tool or by careful sanding. If you are using a CNC machine, this can be easily done with a large diameter tool and pocket operation; Simply clean enough wood so that the surface is nice and flat.

The reason for the surface is that the two halves of the box will be cut from this single portion, and then they will have to fit together without gaps so that they can stick together properly.

Step 2: Cut the casing

The zip file "here" contains an SVG image of the Pen drive case. If you are using a CNC machine, simply download the svg and open it in a CAM package. You can find a completely free CAM package.

Start by selecting the internal routes and creating pocket operations for them. A depth of 2.4 mm is needed for these pockets.

Cutting inside corners with a round tip can often be problematic, but this time it really helps with the design.

I used a 3mm cutting tool which leaves a small radius on the inner corners, which makes it hold the Pen drive circuit board perfectly, so there is no need to worry about correcting the inner corners. The external paths need to be contour profiles and cut all the way through your wood.

If you are doing this with a Manual Router, you can print the SVG file and secure it to your wood to use as a guide. It doesn't have to be super neat, as any internal errors will be hidden from view. If you cut the outline a little larger than the guide, then the external mess can be sanded off later.

Step 3: Add the circuit to the wood

These types of Pendrives are built in the same way and will have a small hole at the bottom that can be used to open the case with a nail or something. After opening the plastic case, you may find that the circuit board has been stuck with hot glue, this is easily removed with a little force.

Once you have removed the circuit board, you will need to glue it to your new wooden box. This is where the hot glue gun is needed. Simply place a bead of glue on the back of the inside of your case, then hold your circuit board in place until the glue dries.

Use wood glue for this as hot glue will not be strong enough. Clean the edges of any dust and coat them with wood glue. Press the two halves together and secure with a snap.hoe of some kind. You should let this dry overnight.

Step 4: Sanding and finishing

Once the glue is dry, you can sand your new case to make it look super smooth. If you want to do this, I recommend that you protect the Pendrive from dust by covering it with adhesive tape. I sanded mine with a range of grits, starting with 80 grit and working up to 320. Then I used a Dremel fitted with a buffer wheel and a little buffer compound to really make it smooth. Finally, the wood is polished with a little wax and left to dry. Thanks for reading!

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