A major challenge in engineering design graphics classes has been the development of semester-long projects, which supports curricular goals while maintaining student interest. In this paper, we will describe a project to develop flash drive casings. The project scenario was structured as a request by a client to design a themed set of flash drive casings and a presentation case suitable for use as a gift to outstanding employees and high value clients. Each student rapid prototyped one flash drive casing of his or her own design. The project was implemented as a series of team and individual assignments spread over the semester, with the product of those assignments returned to the instructors in memo format. This project was implemented in three phases, over several semesters, with the number of students increasing at each stage to ensure that its full scale adoption was successful. The initial test of the curricular elements was made in two, approximately 20 student summer classes. At that time, several challenges were identified. Reflection on this phase revealed a need for additional written documentation containing “project hints” to help students provide designs that meet the rapid prototyper's production constraints. It was also determined that a number of intermediate assignments were needed to motivate students to remain on schedule for project completion. The project is currently nearing the end of development phase 2 and most design issues have been resolved. However, curriculum changes are warranted in response to student conceptual difficulties. As in many graphics design projects, a major challenge has been the development of three-dimensional spatial skills. Students have had difficulty creating designs containing layered structures, particularly those needed to secure the electronics within the casing. As expected in a first semester, first year course, some students have shown an inability to follow detailed instructions. While this weakness is normally only a grading issue, the flash drive covers are prototyped directly from their CAD files, making type of error particularly problematic. One major success of the project has been student excitement in the project and the improvement of their graphics skills from re-creation of existing designs to the development of novel designs.