Apparently part of my brain is american.
In other news, got the design without eye/mouth/nose OK'ed by Teamliquid. So I feel like that's a good alternative.
edit: going to bed so I wont be able to answer any PMs or questions for about 12 hours.
edit2: Just got a reply just now:
While the dimensions you have given me are within the requirements I have stated, what happens when the artwork goes to the machine is the CNC cutter traces along the outside edge (or even an edge slightly inside the outside edge) - creating a slightly larger image than what has been drawn (your image plus 1/2 of the cutter width that is tracing your image). The requirements that I have given are to allow enough room for the tool path of the cutter and still leave enough space for the plastic to flow through an area - this doesn't always mean that what we end up molding will be exactly like a computer generated picture - hence the limitations of 2-shot molding.
The smallest size cutter that we have is a 0.010" cutter - in practice: On the 'mane' of the horse, the black areas on the keycap are most likely the size you drew them at, plus 0.005" on either size (in essence it is 0.010" bigger than what you have drawn). We can off-set a tool path to work inside an image and account for the size of the cutter, however in small areas, we might be sacrificing detail. The mouth for example, we can off-set the tool path on the lower jaw to make this black area larger, however it will make the inside of the mouth less detailed and smaller. Does this make sense?
I will send the modified image to the CNC machine - we are however several days behind in production and I don't foresee this happening until sometime next week. I will let you know when I have a picture for you.
Thank you for your patience!