[graemeklass]

I am making a USB device for my start-up and the top comment is pretty much sums it up. Other tips: 1. For low volume PCB protos (even 3 boards) you can't go past http://www.ourpcb.com for value for money. They have been awesome and very helpful. Ask for John. They can also solder those hard SMD chips and source components from your BOM. 2. For supply chain post your requirements at www.hkinventory.com - make sure you use a temporary email as you may get spammed. Usually it's a hard struggle to get a handful of components (they usually deal in thousands) but in this economic climate I think they will get what they can!

3. Plastic moulds is expensive, but again try posting your requirements at alibaba or something similar. In my experience, get a professional mechanial eng / industrial engineer to design the CAD. This may be 8k to 15k. Again I did a mini tender to three firms and got their responses and then chose one.

Good luck. Feel free to contact me if you have any further questions.