Overview
Custom Wallet AirTag Holder
While not my most complex or challenging build, this project is one of my favorites because it gave me valuable insight into product design and has proven to be both practical and convenient in daily use.
A wallet may not be the most common item to lose, but when it does happen, it’s likely one of the most troublesome. To get some additional peace of mind, I wanted to add a tracker, but existing options like the Apple AirTag and Life360 Tile were either too thick or bulky, so I set out to create a slim housing that could integrate a tracker while also storing a few useful items.
Initial 3D Print
I started with a dissasembled AirTag, repositioning the battery adjacent to the main chip rather than stacking them vertically, which reduced the thickness from 8 mm to 5 mm. The first 3D-printed housing worked almost perfectly, it synced seamlessly with Apple’s Find My network and securely held three coins for emergency parking, a folded dollar bill, and a set of scissors from a Swiss Army Knife that’s proven surprisingly useful.
However, the layer lines often got caught on the elastic slide mechanism, and due to the strength limitations of thin 3D printed walls, the overall housing thickness was 10mm, more than a standalone airtag.
Machining with Delrin
For the final iteration, I machined the housing from Delrin, which reduced thickness by 4.5 mm, improved durability, and significantly lowered friction in the slide. Using a slotting end mill, I cut an undercut feature that allowed the dollar clip to be integrated directly into the body instead of relying on a separate piece. The finished wallet insert comes in at just 6.5 mm thick, secures coins with slip fits, and uses embedded neodymium magnets to hold the scissors in place. This version proven to be durable enough for everyday carry, and doesn’t add much bulk to the wallet.
