So I was fortunate enough to pick up one of the first Raspberry Pi Zeros before they went out of stock. I thought the idea of a $5 computer was so cool I wanted to make a case worthy of that idea. I thought about the design here and there for a few months before deciding last week to get off the dime already! I wanted to make a case from metal, and even if it doesn't really need it, I thought I could have a pad on the top touch the processor (with a little heat paste) to turn the case into a big heatsink. Few metals beat copper when it comes to conducting heat, and copper has such a nice warm color, so copper it was. Here's how it came together (click photos for higher res versions):

First few milling operations on the insides of the top and bottom. The tool marks look pretty rough, but they're very smooth and polish out easily. The two holes on top are for aligning the piece once I flip it over to mill the other side. Finished milling for the insides and a quick polish to dull the edges a bit. First few passes milling the logo on the top. I had to use a .02 inch end mill to capture the little details in the leaves, so I had to take very light passes and run the mill very slowly to prevent snapping the end mill. I only had one and I didn't want to have to wait a few days for another to be delivered. Finished case, polished up nicely with the Raspberry Pi Zero in place. I had planed to polish the entire case, but when sanding some small tooling marks from the top, the brushing effect added a nice contrast to the smooth polished logo. I tapped threads in the top with a small hand tap. There's 4 stainless steel button-top allen bolts that extend about a 32nd of an inch below the bottom, so the bottom of the case doesn't touch any surface it's sitting on. Done! I'm really happy with how it turned out. Now I just need to find a good finish to protect the polished copper and keep it from tarnishing. If you have any questions or comments, feel free to e-mail me.