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I like the polycarbonate idea, but benefit of aluminium is that it takes very little volumetric space. I suppose polycarbonate would need at least 3mm sheet, or maybe even 5mm? I'm thinking maybe for my next one I could try stainless, which could be 430 or 340 grade...

even if the part was going to fail, it's unlikely that all the 3 fixation points fail at the same time. Most gps holder only have 1 fixation point on the handlebar so I am quite confident that in case of failure I'd notice before it happens. My only fear for now is velcro fatigue, which...