I’ll throw my hat into the ring on this one. I’ve got a housing/design for something like this over here. I modeled this using the official mainboard and battery CAD, and printed it all out as a prototype, which all fit together really nicely, in a sub 300mm width package excluding any controller dimensions. I don’t think I could narrow or slim down the design any further, since going any thinner would probably result in really poor thermals, and reducing the width would either structurally compromise it or result in a loss of features like the WiFi module. I suppose you could reduce the height, but that would start causing issues with installing the display and how the front housing attaches to the rear housing. Some have mentioned that JoyCons are a poor choice, but without designing a custom PCB or using some kind of Arduino (both of which I have limited or no experience with), they’re really the best option I can think of currently.
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