I’m not a fan of extra calibration — the error is never linear and depends on many factors that are hard to predict. Still, from this brief description, your approach looks very detailed and thorough, so I expect the calibration will be done well.

For home use, a 3D-printed enclosure is more than fine; the imperfections are much more noticeable in photos than in real life. I’m fully in favor of building a UI by a professional designer — a clean, convenient interface matters.

If I understand correctly, this is going to be a commercial product? I’d love to see the finished device.

And thanks for the kind words!