whoa tons of stuff here…very ambitious project
regarding your foams, grab a thin black pen and sketch your part lines onto the foam, or glue black paper onto the front, or sketch details on to show texture and material break up, or do a quick mask and paint them…
mobile CE is all about materials and “in-hand” feel right now; and not a lot of companies are getting it right (mostly because it’s really hard). I’d think deeper into materials and construction and let that help inform your form factor.