One point what I was trying to make a while ago, is splitting the top section into multiple chunks for starters.
EG:
1.PNG
top_four_pieces.png
The hole are not in the right place, but its only a draft idea anyway.
mddincdbijemigcl.png
The new join supports running front to back didn't render fully to the back but oh well.. again its more "thinking out loud".
Overall idea is that printing a large area can mess up easily. But in 3 sections , if one sections gets messed up, or broken, it doesn't need the whole lot doing again.
The keyboard cutout *almost* is flat to 3D print.. but that would likely need some tweaking and would still need fixing locations adding, which could be tricky as the keyboard could be in the way.
cjbajodepkapcppp.png
Overall idea being the keyboard area would be easier to print on if it was all lay flat to start with.
Plus as
@Icky posted above, removal back panels etc was already considered and designed.
To be clear, this is all just thinking out loud at this point. Finishing the files, designs and concepts, along with trial printing and testing, will take months if not years to complete. We're flooded with so much work already that there simply aren't enough hours in the day.
Some people are likely to grumble about certain aspects of this, but 3D printing is the cheapest option available. A few folks have already printed cases and the results haven't been great. Making the case modular, though, solves several problems at once. It reduces the overall size, makes each part easier and cheaper to print, and means that if a print fails you only need to redo one section rather than the whole thing. It also means a broken part can be easily replaced on its own.
Shipping is where it gets tricky. A "flat pack" style case is far better than shipping a large, essentially empty case, where volumetric weight nonsense drives the costs right up. If it's cheap enough for people to print themselves at home or through a service like JLC, then it becomes a straightforward trade-off between cost and quality. That said, that framing isn't entirely fair, since a modular case can be printed to a really high standard anyway.