You've got a very good understanding for someone who hasn't worked with sheet metal before, very impressive
I've been talking to some of colleagues today and we've come to an agreement that the prototypes will have to be lazer-cut, then bent and folded, to save the manufacture of punches. Even with lazer cutting, it will be costly. most likely around 300-400 alone for just the lazer cutting (I know from previous work I've had done). the only issue i can see, is bending the side panel latches, more than likely will have to be done in a special hand press.
Thinking more and more I may even do the prototype in aluminium, and do most of the bending and folding by hand.
With the side panel issue when using the 5.25 cage for structural support, that could easily be fixed by simply making the catching flange on the side panel slightly higher.
I will have to modify some things on the case very slightly to get it produced, but it is do-able, and it will be done
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