Bitcoin can't be magically brought into the physical world, all we can do is create a shape like coin and insert the wallet seed in it, or the private keys if it is linked with one address. The way bitcoin is designed it isn't meant to function while being in a physical state. I hope you understand the concept of bitcoin properly because what you are asking is not possible. Bitcoin casascius is one of the examples of what can be done to bring bitcoin to the physical world. Bringing bitcoin to physical realm is like converting your Ferrari to a Toyota and we don't want that happening. 

Physical Bitcoin is a nonsense to my mind. It kills the idea of Bitoin itself, it's main value.... It is possible to make some physical coins of Bitcoin may be just for some fun or for someone's pleasure. But to my mind it will not work as it is expected in case when it is in physical format. It will be expensive and non-profitable.... But it is my oppinion. It may differ from someone's.  

Well, these things already excist. Just google for 'casascius bitcoin'. I have one myself, and I think it's really pretty.

I have to agree with milani though. Bitcoin in physical format meant for payments is not gonna work. However, keeping a physical bitcoin for collection/storage can be pretty fun.

BTC credit cards are like an instant exchanger, they convert your btcs to usd or whatever currency you are buying in. This isn't the true conversion of bitcoins to the physical world, what is the use of btcs then if we want to convert them in the end? I see no purpose of buying btcs then just to later convert them again. What can be done is, we can make some sort of credit cards which will transfer bitcoins between users instead of converting them.

Physical bitcoin ,i dont think its a good idea even if that is possible,I mean physical things are tend to be destroyed easily and theft can be more easy any regular thief can steal your bitcoin .But as per i know the purpose was the bitcoin to decentralize and digitize  the wealth , hence here physical form does not fit at all.

Everything features of  bitcoin maybe the mining, transaction, wallet aspect are base on the internet and that's why bitcoin is call electronic cash. Therefore, it is not possible for someone to have physical but such can crave a gold into bitcoin though.  However, there are some altcoin which have physical coin.

In fact I've seen some phisical 'bitcoins' being made before. Most of the times they do not contain actual bitcoins but in some cases they are actually loaded with real bitcoin. These are mainly bought/sold as a collection item (I don't think loaded physical 'bitcoins' are still being made though). If I had the money I would like to have one and use it as some sort of decoration and put it in my room. But mainly to store the bitcoins long term.
Since these are collector items and not real bitcoins I don't believe it would be a good idea to create some sort of physical medium for bitcon. In my opionion that undermines the whole point of it. But that's just me.

how about phisical login and pass from bitcoinwallet?
need to think how to do it unique...

I think that physical bitcoin is a bad idea. Bitcoin is a cryptographic currency, which marks a new development for the world currency market. It is also the advantage, characteristic of bitcoin compared to the current popular currency. we should not abandon its characteristic to use a physical bitcoin.

A "physical Bitcoin" is no more meaningful than a paper wallet.  The coins never leave the blockchain, so they're just as online as they've always been.  When you need to actually spend the coins, you'll have to import them using your seed/private keys so that you can use them.

The difference is that when you get the "physical Bitcoin" sent to you, it's already loaded with BTC and you're given the seed, so it's possible that the company or person producing it could have kept the seed for themselves and would take it later.

They're useful as collectibles but not as much else.
They are not actually present in physical form.  You just have information that is required to transfer the coins that are stored in the blockchain.