... can you find a factory willing to make a small run for a sensible price?
I'll get a quote for 1k, and we'll find out.
If you can are they tough enough to solder to, or is there another way to link them at random stagger?
Soldering is the easy part. I've hand-soldered eroded traces on my wife's Kinesis. Their PCB is a good example of stiff flex which still needs strong mechanicals. See some of the images, here:
https://www.google.com/search?q=kinesis+keyboard+teardown+imagesLinking is the tricky part. Connectors can be cheap, but cables can be spendy - then there's the routing. Hand-soldering wires is also easy - depending on routing, again. Routing must maintain the aesthetic and allow for the mechanical adjustments.
Other items:
- Since OP understands the problems with feature creep, any MX option must not impede the Topre effort.
- The controller PCBs could easily be redone the same size with Ergodox components. Actually, I'll have a look at that part, as well.
- Measurements might not even be needed. If OP exports a row as a STEP file, Altium makes it easy to define regions from any flat surface on the 3d body. Other ecad could use DXFs.