My take on a Honeycomb cutout style wallet card for Apple Airtags.  

Once or twice a year I tend to misplace my wallet somewhere. It usually winds up turning up somewhere in the garage or in the car, under the seat!  An Apple Air Tag would be a great way to help mitigate some of the stress associated with this seemingly recurring phenomenon.

This model is not just a simple infill hack (the infill-hack AirTag Card version was born on ThingVerse btw), or a simple SolidWorks fill-pattern cutout. This model took quality time to get the cutout pattern symmetrical, getting the star pattern around the AIrTag cutout in the middle just right, while maintaining a proper strength to density ratio.   

Features:

• Aesthetically pleasing, filament-saving honeycomb cutout, with a neat star pattern surrounding the middle cutout.

• Though testing, it's a perfect balance between ultralightweight (flimsy) and structural integrity (strength).  My testing showed that thinner honeycomb walls takes a hit in the durability department, while walls thicker than the walls used in the is model (or smaller cutouts) made it bulky and unnecessarily dense in my opinion.  Smaller cutout are also more prone to collect debris.

Printing and use:

• Super-Simple print, I decided to keep the cutout faces clean & flat (no bevels or fillets on them) so it would keep things simple & sharp when printing.  Slices & Prints clean as a whistle!

• Tolerance issues / The Airtag Fits too tight or too loose on my printer - Tolerances and accuracy are slightly different in every printer. I've intentionally created the cutout a bit on the tighter side.

• TIP- for PETG & PLA,  give your print a quick dip in hot water to soften it up for AirTag insertion. 

Fun with advanced Printing Features:

• If you never have played with the ironing feature in Prusa Slicer, this would be a good time, basically ironing makes for a super smooth top surface.  Since this model has two smooth surfaces it's the perfect opportunity to try it out!  More about ironing here - https://help.prusa3d.com/article/ironing_177488 :)

Enjoy!