blacknet,
I've been diving a PRISM for about 4-5 years. I've dove the early prototypes, some of the rentals and my own.
1.
The stock PRISM comes with a plastic backplate that is thick enough to support the rig, yet flexible enough to give some while wearing the rig, almost like it forms to your back. The cumberbund on the BC can be unbolted and moved up/down to adjust to your height/comfort. The cumberbund length can be adjusted as well.
Weight distribution is something of a personal preference, the counterlungs have weight pockets in them, along with standard ditchable and non-ditchable pockets on the BC. This allows you to trim the RB the way you want it.
Almost every PRISM diver I know modifies the unit in some way. I think there are 3 different companies making a stainless backplate. Most divers with a backplate use some form of a harness instead of the BC. I use a SS backplate and the stock BC.
2.
SMI carries a couple of Pelican cases for the PRISM. The really big one (1660?) is much larger than the PRISM and offers a huge amount of padding, I've traveled with the 1650 and had no problem, my last trip the rig was under 75lbs (PRISM alone 47lbs) including the pelican and I didn't even have to pay extra baggage. I was paged by the airlines and quized about the "O2" bottle, but telling them it was empty seemed to satisfy them. Some dive sites are starting to carry 19-20cu ft bottles with crossflow valves so you can travel without your cylinders
( Cortez Club-La Paz, Bikini ). You could probably carry the PRISM on as a carryon without the cylinders.
3.
Inert gas usage depends on you ! Drysuit ? Square or yo-yo profile ? Orally inflate your BC on the surface ? Mask leaks ?
I can go a weekend without a Diluent fill (19cu) on square profile, wetsuit dives. Some of the PRISM divers are buying a spare O2 and dil tank and just swap out rather than go for a fill ( offshore or remote diving ), and sometimes a spare scrubber to pre-pack and just change it out ( kept in a tupperware container ). You can put together a transfill whip and refill without removing the tanks.
I'd be happy to answer any other questions,
Steven