Everyday EDC

02 / 05Side profile

5 cards and 3 keys, in 7 mm.

4.5 mm of card space holds about five 0.76 mm cards. A slot in the top edge takes up to 3 keys.

The top edge steps around the camera on iPhone 11 Pro to 16 Pro, including Pro Max.

Next: Exploded view

03 / 05Exploded view

Resize it with the blue inserts.

Each blue layer is 0.83 mm, about the thickness of one card (0.76 mm). A resize kit adds or removes layers, with screws to match.

Section through one edge, thickness to scale (mm). The back plate's rim is one insert layer (0.83 mm) thicker, for rigidity; with the inserts it walls in the cards.

Next: Assembly

04 / 05Assembly

No elastic. Nothing to stretch out.

Elastic walletMagWallet
Holds cards withA stretched bandFriction, in a 4.50 mm pocket
ThicknessGrows with the cards7.00 mm, fixed
Fewer cardsThe band loosensRemove a 0.83 mm insert layer
Wear partsThe bandNone

Next: Finish

05 / 05Finish

Anodized in four colors.

Type II anodizing: the aluminum surface is converted into a hard oxide layer, dyed, then sealed. The color is in the metal, so it won't peel like paint.

Dyed finishes vary slightly from batch to batch.

Next: Process

Process

Modeled in Onshape. 3D printed and tested. Rendered in Blender.

Goal

Our keys, cards, and IDs are going digital, but the transition is painfully slow. Despite how much my phone can do, I still need a physical ID, a card for places that won’t take tap-to-pay, and cash for backup. I got tired of waiting for this slow transition, so I designed a wallet that fits within my phone’s footprint but can still handle an active, everyday routine, held to the back of my phone with MagSafe.

I wanted it to be not just smaller, but also better, so I used this opportunity to rethink the whole design. I added a spot for two keys alongside three cards and a folded bill, removed the elastic strap most slim wallets rely on, and made it half as thick. Inside, adjustable plates let you set the fit to exactly what you carry, and friction holds everything firmly in place.

Design requirements

  1. R1Fits iPhone 11 Pro - 16 Pro, including Pro Max; clears the camera
  2. R27 mm thick or less
  3. R3Holds 1 card up to a full stack, plus 3 keys
  4. R4No elastic or wear parts
  5. R5Mounts magnetically (MagSafe-compatible)
  6. R6CNC-machinable and anodizable

Process

  1. 01

    Concept

    Card layout, magnet position and camera clearance, sketched first.

    Pencil sketch titled MagWallet V1: back, phone-side and edge views with dimensions, screw callouts and the MagSafe magnet ring.
  2. 02

    CAD

    Modeled in Onshape, sized around the iPhone 11 Pro - 16 Pro camera modules. Shown: the model for prototype 1.

    Onshape model of prototype 1, phone side up: the magnet ring, the screws and the orange insert layers.
    Onshape model of prototype 1 from the back, with the thumb cutout and the insert layers.Onshape model of prototype 1 from the back, from the other end.Onshape model of prototype 1, phone side up, showing the card space between the plates.
  3. 03

    Prototype 1

    3D printed to test phone fit, camera clearance and card hold.

    Prototype 1, 3D printed in black with orange layers, phone side up: magnet ring recess and screw holes.
    Prototype 1 from the back, with the orange layers showing at the edge.Close-up of prototype 1 at the thumb cutout: the orange layers between the plates.
  4. 04

    Prototype 2

    Tolerances and dimensions adjusted, then reprinted, until every fit was right.

    Prototype 2, 3D printed all in black, phone side up.
    Prototype 2 from the back.Close-up of prototype 2 at the thumb cutout, showing the layers.
  5. 05

    Design for manufacturing

    Drawn up for CNC milling in aluminum, with the dimensions in millimeters.

    Open PDF
    Zach's engineering drawing of the MagWallet, rev 2: back, edge and phone-side views with dimensions in mm (113 × 60 × 7, Ø55.2 magnet ring, R11.5 thumb cutout), an isometric view and the title block.
  6. 06Next

    CNC milling

    The final design, ready to be milled from aluminum and anodized.

    The final MagWallet design from the back, with the thumb cutout and the blue insert layers.
    The final MagWallet design from the back, from the other end.The final MagWallet design, phone side up: the magnet ring, the screws and the blue insert layers.The final MagWallet design from the back, along its long edge.

Specifications

Dimensions

Length
113.0 mm4.449 in
Width
60.0 mm2.362 in
Thickness
7.0 mm
Corners
R5.0 mm
Thumb cutout
R11.5 mmpush cards out

Capacity

Card space
4.5 mm1.67 mm of inserts + 2.83 mm rim; ≈ 5 cards at 0.76 mm (ISO/IEC 7810 ID-1)
Blue inserts
2 × 0.83 mmresize kits add or remove layers
Keys
Up to 3
Fits
iPhone 11 Pro - 16 Proincluding Pro Max

Build

Parts
14 + 2 magnets + 9 screws
Plates
1.5 mm + 1.0 mmphone side; back, with a 2.83 mm rim (thickened for rigidity)
Fasteners
M2 countersunk6 mm long with both inserts; tapped 2.5 mm deep
Magnets
MagSafe-compatible, off-the-shelfØ55.2 mm ring recess
Material
Aluminum, anodized
Machining
CNC milled
CAD
Onshape

Everyday EDC wallets are concept products for a design project; nothing here is for sale.