Update:Okay so after a bit more testing and trying to figure out what I can do on my end in the meantime, in regards to figuring out any issues, I have some news.
First I tested the slider in a matias switch setup, with a tactile leaf and no leaf at all, didn't try click as the switches came pre-lubed and even click modded tactiles make zero noise...The tactile feels really, really nice and the second bump that the simplified mechanism produces is now gone so it feels like a SKCM style tactile switch now. The linear is smoother than anything I have ever felt...The polished mold finish combined with POM is a perfect combination.
I even cut off the click leaf protector bump on a stem for testing in an unmodded alps housing(don't want to file if I don't have to, and wanted to test without my top housing) and it feels the same as the matias in both instances, and it isn't lubed at all. I removed the bump as it would catch on the unmodded top housing, and I wanted to test without that affecting the sounds and feel.
I did test an SKCM click modded tactile leaf and standard clicky leaf, on both the slider with and the slider without the bump, no cap in either case. The no bump switch performs as expected and sounds like a normal clicky switch of both varieties. The slider with the bump sounds...off, the click isn't as pronounced, which was expected as the bump is there to protect the leaf from being crushed by the cap. The switch makes a faint click before actuation, right as the click leaf bends towards the slider and hits the bump, and during release the click happens again, but louder, almost the same as the normal click but sounds different. The faint click isn't as noticeable during normal use, but the second click is, obviously. There is a chance that putting a thicker lube on the bump could reduce that click and make it non-existent without affecting the normal click, but I have no lube to check this theory with.
I didn't expect that to happen whatsoever and don't know exactly why it makes a sound now, as the click leafs hit the slider without the bump at the same points during the actuation, but make no sound. There was no way to have heard this prior as no 3D printed prototype had this happen, most likely due to the part being of a much different structure because of the printed layers and how different the processes are in regards to how the crystalline structure forms during cooling.
Now during this testing I learned something important, the switches don't wobble as much as initial testing did. My initial tests were done with my top housings, which means the top housings need to be adjusted to have less wobble, because this is unacceptable. As well there is no noticeable catching of the switch plate leaf, which means it is probably due to the top housing cavity being off enough to put the slider in an odd position and binding the spring.
So this means there needs to be a little work on the top housings to make them perform as they should. As some of the dimensions are on the absolute edge of the tolerances and the wrong side that I would prefer(meaning some are on the large side, when being smaller than dimensioned is preferred), which causes some issues.
I know this is a long post, but it is important information, and I am trying to perfect what I can at this point, as I don't want the product delivered as it sits. I hate delays as much as anyone, but I can't deliver a crap product. I will probably have to spend money to fix these issues and I hope it doesn't cost much as I can't afford large expenses...
Also rep was still on vacation this past week, so I haven't received the info I was waiting for.
TL;DR: You will have to read sorry.
