Just a thought, what if instead of adding depth, you added width for the extra components and jacks? With a slightly more ergonomic feel, almost a cross between GBC and GBA, more so rooted to the GBC design. Also what are you using for 3d modeling, and who are you getting your quotes from? Earlier this year I found a Maker Space near me which is about $50 a month, but gives me access to laser cutting and 3d printing. Worth looking into, if not for mass production at least prototype runs for 3d prints and pcb design. I realize this could be an entirely new project altogether, and in no way mean to diffuse your project, as it is looking pretty good so far.
Thanks! It'd create a lot of extra work as it would involve moving all of the button and ports and it'd make the device even bigger, unless you're picturing something different to me. I'm designing everything in autoCAD. There's a space here but the printer is broken at the moment and it's an old reprap model anyway- will probably need higher precision and thinner layers for creating a mold pattern when I cast it in resin. This is my first big project so I'll maybe consider doing something more ambitious when I've finished this.
