For one, such wallets are not optimal for travel, since they are easily recognizable as purpose-built devices made for storing and spending bitcoin. They even tend to be prominently labeled with brand names and logos suggestive of their purpose, so that even someone unaware of hardware wallets might guess their purpose. I would prefer to avoid the possibility of airport security or similar types recognizing the device,
A bit off-topic , but I use for travel Tangem 2, not DIY, but cost affordable and almost purposely -disguised hardware wallet. You may even attach to its surface some film holding recognizable bank name to camouflage the stuff further or misrepresent it as a luggage tag,all depends on on your creativity.
Not off-topic at all (in spite of thread title
), as I am still considering non-DIY options, as long as they aren't too conspicuous. Tangem looks like it might fit the bill. With it's credit card size you could keep it in your wallet as you go through airport security. I see they also have a finger-ring option coming soon which looks cool. I'd probably go with the card though.
Another credit-card size option, and very discreet indeed. Will definitely consider this one, thanks!
A laptop-sized airgapped device is also unsuitable, as another feature I seek is maximal portability, something that could fit into a commuter-size backpack along with my main laptop and other items when there's no room for extra luggage. So, I'm looking for something that combines the best of both worlds, the portability of a purpose-built device and the non-conspicuousness of an airgapped all-purpose device such as a laptop. For example, a Raspberry Pi might fit the bill, as long is it can run Electrum. Would that be possible, or are there other ways of making such a device?
If Raspberry Pi might fit your needs, have you consider Mini PC (e.g. Intel NUC) or Handheld PC (e.g. Steam Deck)?
I hadn't considered that option, but it might make sense to buy a cheap used Steam Deck and replace the OS. Would definitely not raise eyebrows at airports, since it's such a popular gaming device. It might even be possible to airgap it by removing the wifi and bluetooth modules, considering how easy it is to replace the SSD:
https://www.tomshardware.com/video-games/handheld-gaming/how-to-upgrade-steam-deck-ssd
While looking further into this option, I came across this info from an Amazon listing for a J3R180 card:
Our cards work well with all standard ID card printers, including DC150i and Fargo HDP5000 Zebra P330i.
So for someone looking to go cloak and dagger on their HW wallet, they could make a Satochip DIY, then print it to make it look like an ordinary ID card of the type used at workplaces, schools, gyms etc.