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I believe he has them printed at Shapeways, or at least he did for a while. With Shapeways’ nylon prints I’d be quite confident they’d hold up to a fair bit of abuse. Though do note that his design doesn’t have the little shelve at the bottom, probably with good reason.
If CAD skills are the limiting factor I’d be happy to draw something, the Shapeways prints aren’t going to be cheap though.
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Sounds about right.
While the shelf seems like the obvious solution, I'd expect in typical UK conditions it'll fast fill with mud (even with those drain holes), especially if used under the downtube and that is going to be heavier than intended and pretty grim. I think the 'lip' design other manufacturers go for (thinking King, Salsa etc) paired with a supported bag is probably the way to go if you need the extra support.
If you're feeling impatient, there's a chap up in Scotland producing something similar and selling them through another chap in Scotland: https://backcountry.scot/product/dewidget-strap-deck/