Long post incoming!
I have been taking some steps to start creating physical versions of the console and its elements. The first thing I will make are the games. I am thinking about a Raspberry-based console, so I believe the most practical and simple option is that access to the games is done via USB (each game would be a flash drive with a single file that would be the game rom). I've been looking for a pendrive model with simple shapes and easy to fix in place into a cartridge, so I got these ones:
From this model I have created a 3D design for a cartridge containing the pendrive and with the external shape that we are looking for. The assembly would be done with 2 self-tapping screws, as follows:
The final cartridge will look as you see here. It will have a front sticker with the game logo or cover and a rear sticker with your typical warnings to not disassemble, etc.. Underneath, it has 2 chamfered cylindrical guides. These will help align the male USB with the console's female connector when inserting the game. At the front there is a slot to lock the cartridge when the console is turned on (similar to the SNES) and at the back there is an indentation that will serve as a handle to insert your fingers and remove the cartridge (similar to Genesis cartridges).
The inner design of the 2 case halves would be this one below.
Now I will have to try to make a 3D printed prototype of these parts. With it I will be able to test the fit, clearances, etc. And if it works well I will order them in high quality (resin) and create the stickers.