With 3D printing the new big thing, I'm surprised nobody has 3D printed a replacement A500 or A1200 case yet. I know companies like Sculpteo will let you send in a 3D file and print out your object. Anybody considered it?
We can do it now. All that is needed is one of the following to happen:
a) An individual with the talent and time to measure and hand-input the plastic case measurements (and all the nooks and crannies), verify that it can be printed by at least two services, then sell the finish product from the service's online store. (Unlikely)
b) Same as a), but the individual has access to laser-scanning equipment, and knows how to properly clean up the rough laser scanning. (More likely)
c) An individual makes a 'rough case' (basic size and shape, right screw placements and port openings), and open sources the design. (See Creative Commons design licences). A group of people then gradually refines the design over time, and by the end of a year or so, the case gets to be about a 99% match of the original. (Most likely).
If you want to make this happen, I would recommend that you pick a 3D printing service with a free modelling tool, and work on the c) project. Take any cases you have/can find and measure their rough outlines, and start building the model. Verify that the tool says it can be printable, and make one.
Refine your design when you get the printed case, and once your are happy that all the components fit, release the case design to the world.
Get a group of like-minded people to refine the design, and you can split the prototype cost. (Ie, if you have 5 people, at every major design iteration, the next person in the group buys one 3D printed case from the vendor, and tests it out. From their results, you work on the next design iteration, and the next person buys the next case.)
