Hey man, I was definitely planning on using some form of molded plastic or ABS. I'm not sure what material you were envisioning that is so fragile.. Fiberglass???
I contacted a few plastics molders and they were only interested in jobs of 10000 or more. I think thats a bit out of my league for now.
The problem is the cost of developing an ABS mold. If the demand was there, and I could convince a bank that there were 10000 people dying for these things, then maybe we could get this thing done. For now though i think i may have to figure out another way.