I've been toying with the idea for the last couple of years of using the old case part of my collection to create moulds in which to create new case parts from.

My thought was to go beyond duplicating the parts and explore the possibilities of using metal frames when casting new parts to better disperse the force of opening and closing screens or high stress points (like the Duo Mini dock's spoiler release handle thingy). My plan was to look into it when I had free time and post to 68kmla if I could start making parts.

Using a 3d printer is an intriguing idea. I had some run-ins with a startup company looking to deploy 3d printers into malls so people could print out custom iPhone cases, jewelry, etc at my last job. If design specs for case parts could be open sourced, then replicating broken case parts might be simple as printing it out at the mall or getting really chummy with a 3d printer owner.

3d case scan might make replicating parts faster? http://www.makerbot.com/blog/category/scanner/3d-scanning/

I'll see if I can connect with the 3d printer people and get their input on the idea and I will finally look into DIY injection molding for some simple case parts, like the PB1xx port cover. I'll post if anything works out.