what i was trying to do
Steno key geometry is nothing like a standard board, so I modelled all 25 keycaps from scratch in two profiles rather than adapting an existing set.
what broke
The fingers inside the keycaps kept snapping. I kept answering that by making them thicker, and they kept breaking, until on the fifth revision I stopped arguing with the material and designed them to flex the way PLA already wants to. They held. The case took two revisions. The PCB worked on the first.
where i am now
It works, and it was the first thing I designed where the mechanical, electrical, and software sides all had to agree with each other. Learning to actually write steno on it is the part I have not done yet.