"the real challenge will be to redesign the N900 and produce a new chassis"

Firstly.

It isn't a "real challenge"
It's been done.

I did it already.

I created a finished n900 tough case in antler.
Did a few other n810 and n900 parts I needed to replace as well...
(I have done for many years now ..and still do... a great deal of my work in resin copies ...)

Then did castings of it.
Then did multiple castings in virtually indestructible resins.
The resins can be given whatever textures and colors one desires...
Even introducing foreign products into the resin as a powder...flaked metals...antler...woods ...stone...gem ...whatever...to give enhanced "feel" and weight to the resin...
It is hard to tell the difference between the resin copy.

It is stupid cheap.
Cheaper than any other production method to date.
(Hmmm....actually 3d printing may be coming close to cheaper...now...but not more durable for sure....)

Chassis is no different than the case.
fine finicky parts not really a challenge.
down to 1/132 of an inch detail can be achieved.
It is just as simple.
As long as the original prototype has been accurately made ...all copies will be identical.

Even did video.
Demonstrating the stress testing of cast resin ...
blunt force ...multiple hits with sledge hammers...
drop tests... from heights exceeding 2 stories....
even crush tests with vehicles running over the examples...
It takes a humongous amount of deliberately applied damage to scar the resin copies even.
The link to the thread is in my signature.


Flat out.

It will not happen.

For the most cost efficient method of virtually indestructible reproduction ....
It garnered ....literally ..zero interest...
in any movement towards implementation for our nxx0 devices then.....

Doubtless it will not get any interest again.

Since then.....I took down the site a month or so ago now...where the videos and downloads were posted ...
after maintaining it for years....
with such a lack of interest...
nxx0 mass parts production does not interest me any longer...
better things to do..
better things to spend my time on.