The best thing about these customized flash drives is that they can be as big or small as you’d like them to be. Want to make one in the shape of an airplane? Sure thing, but it probably wouldn’t be very portable. The best one I’ve seen was in the shape of a switchblade knife. Press the button and the USB section pops out as if it was a knife. That’s pretty cool, but don’t take something like that to the airport if you know what’s good for you. 
But really, the people who really order these drives are usually marketing folks at larger companies. It’s amazing how much marketing you can do for your business when you’re able to sell (or give out) cheap USB drives with your company’s logo printed on it. You don’t have to go crazy here and order them in weird shapes, though it probably would help. I mean, who would forget a custom flash drive in the shape of a small pirate ship? Nobody, that’s who! (And yes, I’ve seen this as well)
The biggest issue most people have with promotional USB drives is the cost. Yes, they’re going to be more expensive to create than your typical drive, and thus, that cost gets passed onto you. That’s fine if you expect to have a certain return-on-investment with your campaign. If you expect a certain number of new clients, that may work just great for you to spend a little extra on cool gadgets to help out your cause. And really, at the end of the day there are fewer things better for your business than being able to do something like give out customized USB flash drives.
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