I wanted to avoid using a soldered usb plug, and add copper pads directly onto my board to act as a usb plug.
Now I wanted to know how thick the board should be, in order to have a snug fit in any USB port.
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I have a commercial version of what you are trying to build:
I measured the thickness at the end where the pads are with a pair of digital calipers, and it is 2.20 mm. The blue and black sections of plastic are flush with each other, there is no lip although there appears to be one in the photo.