Just a quick question about the tool (which seems great, btw, from the little time I spent with it... thanks for making it available, though I may end up designing my own to meet special needs)
What is the minimum distance you would suggest between a hole and the border of the plate? Let's assume you do a single key column, is the default result (without "padding") sturdy enough for a plate+pcb mount?
I ask because since AcidFire's project doesn't seem really alive (it's a shame, but I can live with it, though I hope AcidFire and his family are fine), I'll probably resurrect my own Ergodox variant project.
Problem is, I consider creating independant columns. It allows to adjust the staggering (and also will be a LOT cheaper for PCB, since you can do 12 identical single sided small PCBs, which can be ordered for a much lower price than 2 large ones.)
Also, I enjoyed a bit the height variation of the Logitech Wave, and since I cannot really use special keycaps, I'd make some columns higher than others. A bit like this, though with flat colums for the plate and PCB (at least at first
)
http://i.imgur.com/yZKLKCe.pngThe thing is, the 0.75"-wide plate seems awfully narrow once you've put the switches holes on it. Even more for 1.5mm thickness. Seeing how laser cutting is expensive, I don't want to order something just to discover I can only throw it away...
I have some leeway in that I can stack the plates and earn 1-2mm, the the keycap motion also put some practical limitation (even if in theory there's 1.6mm clearance between keycap and plate, with wobble, that would probably mean a regular collision between keycap and plate if I'm not careful).
Also, I'm curious to know that the best cost-effective metal plate cutting service available currently...