Slice this!

[ednisley]

beef it up just a tad

I'd be tempted to fair an arch over the whole back side, with the knife slot built right in. Maybe add a recess across the arch for the elastic strap and punch an integral pen socket on the side. Benefit: no sharp edges or corners, EZ on the fingers.

Your stylin' wallet whomps my saggy belt pack...

[jsc]

The pen cap really wants to be printed in a vertical orientation for diameter accuracy, which is why I have it as a glued-on unit. But maybe if I did go the whole bulky arch route, the whole thing could be printed vertically, with no need to worry about bridging. I could lard it up with containers for several other gizmos I've got laying around as well. A Tile locator, a USB thumb drive...

[jsc]

Erik, using one perimeter does the trick indeed. I think maybe what is happening is that if you use two perimeters, there is no space left over to use as an anchor point for the bridge and it loses its mind.

With a single perimeter, the bridge even occurs in the sane direction (across the gap, instead of lengthwise to the edge).

[ErikAkia]

I have not tried it but I think you can tell S3D to use the one perimeter starting at a particular layer by using 2 process.

[jsc]

I updated my model to bulk up some of the dimensions and reversed the orientation of some of the fillets. The infill problem was definitely due to the too thin perimeter on the bridge layer, it works fine now.

[jsc]

Latest revision: added a low profile thumb drive holder to the top plate. USB Type A plugs are a nominal 12x12x4.5 (mm), but you have to allow for a certain amount of clearance.

I solvent bonded this pen cap with IPS Weld-On #4 instead of two part epoxy, and it is working fantastically well.

[jdacal]

Looks great!

[jsc]

Added a holder for a double ended screwdriver bit. For storage, there is a horizontal recess at the rear of the tube which allows the slot screwdriver bit to sit further in. To use the Phillips head, you can pull it out and rotate it 90 degrees so that the straight bit stops against the face of the recess.