First prototyping is finished, there's some pic's below
All looking pretty good, main issue is getting the cable runs neat - something we couldn't do without putting it all together - hence the need for prototyping. VESA/HDD drive mount has been re-designed around a modular mounting bracket (to the case itself), so there's scope to add alternative brackets based on ideas and popularity. Sits nicely on a desk both with the bracket attached and not.
Main points of that need addressing:
All cable lengths need adjustment. Input seats were all spot on though, nice and sturdy!
Addition of clip points for cables, running them loose doesn't look great.
Addition of detail outlining cable runs. Could get confusing over what goes where!
Might need to raise the USB hub slightly for better clearance & run cables underneath.
HDMI cable looks rather large & unruly. Can't go for a solid adapter as their too short, but can't go for a very short cable run due to difficulty of manufacture and high failure rate. A possible solution could be swapping where the power button and HDMI inputs are, thus hitting two birds with one stone and neatening both runs up.
Possible scope to reduce footprint slightly on the RCA/Audio side of the Pi.
Other than that, we've done very intensive testing on the electronic side of things, and the plan is to ship these kits/cases with a ruddy decent 5V 2A Power Supply. Hub OC protection was tested too, and everything worked as it should!
Other than that, just general detailing & styling, but shouldn't look to shabby in a nice black finish (wife proof at least).
The next hurdle will be IM tooling!
Prototyping pics below. . . . .