I'm about ready to order a case for my HeaterMeter(s), I've been looking over this thread and I must say that I honestly don't like the look of the case with the 4 screws on the corners, I much prefer the square case. I understand the problem with the smaller square case is it is held together with tabs, and tabs made on a 3D printer aren't very durable?
I realize there is not a lot of room to put stand-offs and screws in the case, cause the electronics are really jammed in there, and you can't really make the case bigger without causing a problem plugging in the probes, power, blower etc. Since I don't have one of these cases and pictures are scattered all over this thread its hard for me to get a firm grip on what is possible, but here is my idea anyways!
I was thinking perhaps you could mate the top to the bottom using a tongue and groove type junction on the bottom, and two screws on the top (above the display). You would mate the top piece into the grove on the bottom piece, then hinge it closed and put the two screws in from the back (or top) to secure the unit together. I am not sure if there is room on top of the rPi board for a standoff and a screw, I know there is room on the side with the SD card, but not sure about the other? If there is no room on the other side you could either blow the case out a little larger on top to fit the screw (I think an HDMI cable will reach even if the jack is recessed a bit, and who uses the HDMI anyways?), or you could put the screws in from the top (instead of the back) and build a block of plastic on the bottom that extends into the top (on the top edge), hopefully there would be room for this block of plastic under the rPi board? Then a screw could go through the top into the bottom on the top edge of the unit (screws on the back would be preferred)
If all this is a no go, then perhaps just put the tongue and groove on the bottom, then in the center at the top put one single extra circle of plastic (like the 4 on the corners of the case currently) and put one screw there from the back to secure it, though I would prefer a completely square design like the original case...
I know its hard to put into words, hope I did a decent job...