Make the base of the peg connector a bit thicker than the rest, that way, it won't be as much of a stress raiser. You can only get away with it being flush to the top of the keycap like that if you have a round stem, The square one that meets flush will have significantly more stresses where it meets.
It's starting to look really good. How hard was it to define the front mesh (that the finger contacts) ?
The front mesh was not too hard. Tho SketchUp isn't very helpful with making round surfaces. There was a little trick to it, but not too much. The rounding of the edges was done by a ruby script I DLed.
I'm not sure what you mean with the pegs tho. Is the base of the peg connector the but round the keycap, or the bit that connects to the stem of the switch?
And about the round stem...I'm not sure if the stem gets so much force that I need to design it so carefully. Also given the way the plastic is laid out, I don't think there isn't much benefit between round and square(?). Also a round stem makes some bits particularly thin.
I dunno, I'm going to print this one out first and see how that goes. Also I don't think the reprap can print the curved surface. I'm thinking in my mind that no matter that orientation I print it, I can't make the curved surface...
If I print from the base to the top, the surface becomes this roof thing dangling in the air, that the RepRap can't print. If I start the other way round, the curved surface would face the table, and once again we can't print on air...