Well, not to burst your bubble, but the overall design looks to be very constraining. That is, you can only load your pack and bear ball one way. I usually vary the way I pack up in the morning by the weight. If my food is heaviest, it goes in second, on top of my bag and cloths. As my food gets used, this always reverses, on the trail. My sleeping cloths, down jacket, sleeping bag, and compression bag weigh in at about 3.5 to 4 pounds, depending. My food for a single day is about 1.1-1.3 pounds. With a 2#1 bear ball and food for a day, it will be the lightest of the two load ready pieces...usually in the bottom of the pack. I suppose I could flip it over, but, I would really prefer a symetrcal design that allows it to be placed upright or sideways, and, in any position in the pack.
Typically, I place my lunch in my pack pouches (a piece of cheese, some nuts, and some candy pieces.) After breakfast, I load my pack for the day. I rarely open the pack. For example, on the NPT, I opened the pack once because I forgot to place some drink mixes in my water pouch. My mistake, not the system's fault. This was the only time I needed to open the pack. At night, I empty the pack (set up my tarp first, then bedding, then stove and supper.) The bear ball, whose ever, is always in the way. If I don't need a bear ball, I set a bear line before supper.
I tend to small packs. A 650ci bear ball is HUGE. I have used a BV450 for 7 days in the past. I somehow don't think I would ever need something that large.
That said, I do not think a lot of people hike the way I do. For two weeks I was out on a cnoe trip through the St. Regis canoe area in NY. Good fishing. For 9 hiking days I was out along the NPT. I spent another 4 days with the family at Lake Durant and one day waiting for my pick-up at a lake. My total pack weight for the trip when I left was 23 pounds, but I dropped food at Lake Durant and filled my fuel bottle (not really needed.) I got three comments about the size of my pack "...glorified pocket book...", "...you sure you have all your gear?" (as he eyeballed the pack) "That's one small pack your carrying." Volume, small volume, usually means lighter. Idealy, a 375ci bear ball would be ideal for a weekend.
I understand about the strength of curved surfaces. Idealy, as you say, a round container would be best, but they are difficlt to carry. Have you done a study on what was the minimum radius a bear could bite on was? If you have, what were the results? This would dictate (along with overall strength) how close you could bend the corners. I suspect that most any radius at 90 degree corners would be enough to deter a bite when cradled in a bears arms. I also suspect that a 7" width would be required to prevent a bear from biting directly on two surfaces. Regardless of the strength of the bear ball, I believe a bear can easily crush one if it fits between his jaws enabling him to apply his great biting pressure. Not sure an the asymetric design will deter this. It really needs to be tested.
I would also suggest you loose the flip levers. I don't believe a bear can open them, but, if he presses on one and flips it up, he could grab it and carry it off somewhere. A bad thing to loose a weeks worth of food, whether the bear gets it or not, though better for the bear if he doesn't.
Anyway, a great first effort in design concept. The comfort level while carrying it looks second to none, and far better than a Berikade or Bearvault. It may indeed be worth the extra couple ounces simply because it carry's better.