>Would a Pi Zero W work for this, or do you need a full-size Pi 4?
I tested Key Mime Pi (the keyboard-only version) on the Pi Zero W and it worked great. I haven't tested TinyPilot on the Pi Zero W, but I think it will work. The video encoding is happening in the HDMI dongle, so it doesn't hammer resources much. I don't have a USB to microUSB adaptor on hand, but I'll order one now and see if it works.
>be able to package everything into a tiny 3D printed case.
Yeah, that would be neat! One of the biggest issues I have with TinyPilot's setup right now is that it looks kind of like a bunch of random hobbyist parts stuck together. A 3D printed case would be good and wouldn't have the heat issues that Pi 4 has.[0]
[0] https://www.jeffgeerling.com/blog/2019/best-way-keep-your-co...