I'm working on a design for a cardboard (and possibly thin plastic sheet) case that can be printed off at home on a standard A4 printer. Problem is, max media thickness wise, there's no such thing as a standard printer, so I was wondering (and would greatly appreciate ) if people could give me some idea of the model printers they have? Obviously the thickness of card I can use has a big impact on the design of flaps and tabs etc..
I think you make this too difficult! Just make something that prints on normal copy paper, so the user can cut it out, and use it as a template for his building material. I realize that depending on the thickness of the material it would change the dimensions of the template, but you can simply solve that by creating several templates for different material thicknesses, leaving some tolerance around the connector holes etc. Almost nobody will have a printer that can print on cardboard or thick foil, so printing a template on normal paper is the only practical solution.
Also, some people might want to line the inside of the box with aluminum foil for shielding, that will only work if the ends of the aluminum overlap (and touch) to form a closed "faraday cage". You might want to adapt your design to make that possible.