I"m a Mechanical Design Engineer that works for a electronics company, I have experiences designing Injection Moulded enclosures to house PCBs.
Can you provide a .step (3D model) of the PCB, Altium designer can export this format. We could then take it into a 3D CAD package and design a case. I would like to have a go a designing something that has some standard mounting locations.
Steve, have you had a chance to look at Eric Baird"s wonderful Lego case design?
It would be terrific if you were able to get involved with that project…I"m thinking it might make sense to do the design as a "pseudo-Lego" case, so that it looks like a Lego case, but is a bit more robust.
Please note, this is just my take on the design, as there are more than a few Legoholics wanting to do the work in real Lego! But the mounting of the board seems to be a problem, and it sounds like you might be able to "Terminate" the problem (spoken in an Austrian accent, naturally!)
Even if you have some design ideas ready to go, that thread would be a great place to get stuck in!
I hope you don"t mind the "nudge"….