Customised PCB and Connector Assembly
It's also possible possible to have a 180 pin edge connector + two pcb guides and emi shield on card for mechanical sturdiness. It will also have benefit of being easy to produce. If there are so much concerns associated with pin count, it may be a solution.
Push pull edge connectors will have durability equal at least to USB pins. Female type connectors are available with different durability levels.
EMI shield stamping > http://www.alibaba.com/product-gs/471801802/hot_stamping_shield.html
Solder on EMI shield are now a stock item in industry. They are damn cheap, even custom ones.