I saw the Cascade Wallet and printed it in PET-G and love it! I then realized the opportunity to create a remix and make some minor improvements using PLA to add an ID / Badge holder on the opposite side since I carry around 3 or 4 additional CACs and Tokens for Windows authentication between accounts. What was already on Amazon or elsewhere were too much for my taste and I wanted remix this and see what I could do with it.

I thickended the front wall where the lever action is at because my first print cracked from being too thin when pressure was applied to pop the lever loose in order to slide it up and down. Also, after printing it numerous times in PLA, the slot cutouts for expansion as an ID / CAC / TOKEN was too tight and modified the original by about .3mm and it fits just about perfect. And more or less, it was too restricted to allow the lever to do its job, or too thin and the cards slid freely, which we don't want as we're walking around performing our tasks!

Remixed using Fusion 360 and when Printing at .16, I found it ensures minimal defects during printing, creates a better overall smoother appearance, but if you want to experiment and dial in the settings more than I have, feel free. The current configuration takes 3 hours. The Cascade Wallet didn't need supports, but I found it beneficial after creating the ID slot insert, the long overhang at the top needed something to hold it to prevent print sagging, so “snug” supports are used for the middle area of the overhand / bridge.