I won't add pictures as there are decent ones here, unless people ask for specific close-ups:
http://www.dsi-store.com/cases/show_book.php?isbn=519
I received my DSI case 2 days ago, so this is somewhat preliminary, but so far so good.
The case is a tough (ABS?) plastic, with a metal pinned hinge, and thin foam rubber padding to prevent scratching the Axim when inserting it in the case. The flip cover has a sliding catch to lock it down over the screen when closed. The finish and colour are so close to the Dell case that it is hard to tell the difference.
All buttons, slots, ports, and the speaker are fully accessible when the Dell is in the case, a nice feature. No need for the leather punch!

Or Dremel?
The rubber grippers on the sides are also exposed, a nice "touch". The on/off button on the top of the Dell face is the only one covered, which seems odd until you see how they address that. There is a small plastic button built into the case, positioned directly over the power button. Press it and the case flexes easily and just the right amount to activate the on/off switch. It's actually easier to operate the power button when the Dell is in the case than when it is not!
The flip cover stops at "notches" at approximately 45 degree increments through 90, 135 and so on. 45 and 90 are good for shading the screen from bright sun glare. One position that works when the Dell is NOT in the case, but not when it is, and would be really handy to have would be the 270 degree position. If that was workable, the Axim would be able to rest on the desk at a nice angle to use as a clock or for other purposes, using the cover as a prop.
Another concern with the cover that will make it less than ideal is that it will block the IR device so it can't be used with my keyboard. Simple enough to take it out of the case, but since all other ports, slots and buttons are reachable, it's just too bad that won't work.
The Ax will also not rest in the cradle when in the case. However since I can use my Sync cable this is not a huge issue...except I can't rest the PocketPc at a nice angle, using the cover...dang it again!
The cover has the knobby thing which takes the belt clip. After figuring out how to attach the clip (not at all hard, but mine came with no packaging or instructions), I can see how some people might like it. Being not a pocket protector type (Monty is on my side!), I don't think I will ever use it, except perhaps for clipping it somewhere in the car. If I decide I really don't like it, there is always the Dremel!
The battery cutout for the extended battery I am hohum on, mostly because I don't have the big battery. So I wish it was an option. In other words, a little snap in piece to cover the regular size battery, and give that extra bit of protection would be nice...but on the other hand that would add a little extra bulk and weight.
All in all I like case, despite the concerns. When quick easy access to all functions, and armour (as in field work) is required I think it makes a good choice.
One possible way to address the cover issues, might be to make it hinge from the underside or back of the case. This would put the cover on the other side of the IR device (below? behind?). Then a thin mirror like material like mylar could be used to reflect the IR signal from the keyboard. The battery cover I mentioned could also be designed to flip out from the back creating the prop or stand for various purposes.
hmmm, here I am designing out loud... any patent lawyers present??
Anyway that's all for now! Questions?
