do I need to buy a Micro SD separately?

No. This model doesn't have a Micro SD card slot.

Came with no instructions. Are there online instructions available?

It's a rubber ducky. There are tutorials online (both in text format and in video format AKA YouTube).

Does this need Arduino drivers just on the programming computer, or also on the target machine in order to function as an HID and execute kenystrokes?

You will need the Arduino IDE to program that BadUSB rubber ducky.... But you don't need it for the "victim PC"

How can I open the metal case (without destroying it) to get to the atmega32u4 inside?

The cover for the PCB is pressed into a shell. It's either a rather tight fit, or glued. You may be able to pull it out with pliers if you're ok with damaging the contacts and possibly cracking the PCB. Ideally there is foam lining the top, so dremeling it with some time would most likely work. Sorry for the long winded and not quiet conclusive answer.

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Description

⚡ Hack your world with the BadUSB Beetle — where speed meets stealth!

PLUG AND PLAY 5 V POWER - Reliable USB-powered operation ensures hassle-free integration into your projects.
ARDUINO LEONARDO COMPATIBLE - Leverage the power of a virtual keyboard and HID device with seamless Arduino IDE support.
COMPACT LIGHTWEIGHT DESIGN - At just 9g and pocket-sized, it’s perfect for on-the-go prototyping and stealthy builds.
LIGHTNING FAST 16 M HZ PROCESSOR - Experience seamless coding and rapid execution with the ATmega32u4 core.
VERSATILE I O FOR CREATIVE CONTROL - 10 digital pins and 4 PWM channels let you customize inputs and outputs effortlessly.

The HiLetgo BadUSB Beetle is a compact ATmega32u4 microcontroller board running at 16 MHz with 10 digital I/O pins and 4 PWM channels, powered by 5V USB. Designed for Arduino Leonardo compatibility, it enables virtual keyboard and HID device emulation, making it ideal for advanced DIY electronics and security projects.

Brand	HiLetgo
Package Dimensions	8 x 5.59 x 0.79 cm; 9 g
Item model number	3-01-1521
Manufacturer	HiLetgo
Series	Bad USB Beetle USB ATMEGA32U4 Development Board for Arduino Leonardo R
Processor Count	1
Memory Technology	SRAM
Memory Clock Speed	16 MHz
Power Source	USB Powered
Are Batteries Included	No
Item Weight	9 g
Guaranteed software updates until	unknown

HiLetgo BadUsb Beetle Bad USB Microcontroller ATMEGA32U4 Development Board Virtual Keyboard for Arduino Leonardo R3 DC 5V 16MHz

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