same here since covid Zynq series prices has gone thru the roof ... the 30 and 45 ... we managed to find some at 180$ usd / piece
Now, we use the Myir boards and designed a carrier for them, lan rs485 etc ... works very well ... we have more rom / ram, they can customize ...
theses series :
https://www.myirtech.com/list.asp?id=694designing from scratch in a short timeline, as other wrote is not viable ....
even with the Myir boards, it took us 10 months to iron out bugs in the carrier design, usb interface, sd card, emmc storage, gpio's, esd protections, temperature, vibrations, trace lenghts / impedance matching ... etc ...
it is an industrial use we have for it ... it runs Petalinux and FW goes thru Vivado who's a big piece of .... gigs
oh and 25 of theses carriers and cpu board cost us around 1K$ /ea for a 12 layers, 15x 15 cm
Next one will be in the Artix series or more powerful, but price a 10x times more ..... well see
@op you surely can find dev board as linked, it would be a matter of building your os fork / features etc ....
thoses z-turn board series seems good, seems to have the raspi sizes / foot print
good luck