Taking a closer look at the output DXFs I'm wondering if the problem is the size of the middle pieces, which the holes must be in the center of. It would be helpful to understand how the width of the middle outline pieces are calculated. I also wonder if there is a minimum distance required for particular hole sizes using particular materials. Perhaps a M2 hole can be 2 mm from the edge in stainless steel, but would need to be 3mm from the edge in Acrylic, etc.
Also, what is the best resource for understanding all the precise measurements of the switch holes, stab holes, distance between them, etc. I see a lot of that is spread out through this thread, and I know Cherry has some measurement inform in their product sheets, but I'm curious if there are good online resources that explain all the variables for different switch types, different keycap sizes, cherry vs. costar stabs, mx and other switches, etc.
Lastly, for those who have built sandwich cases using Swill's tool, what materials did you use, what cutting techniques, how thick were all your plates, and how many layers did you use? Curious to hear what has worked, and also learn from what has not.
Thanks.