Here’s my best effort at fixing the Ergodox thumb section under the constraint of still using a flat sheet of laser-cut acrylic and standard sized keycaps.
It’s much more accessible, especially for people with small to normal sized hands; all 6 thumb keys on each side are comfortable and convenient (but the back corner thumb key does require the extra tall keycap, so it can be pressed without running into the key in front of it).
https://i.imgur.com/puH1Ge4.jpg ; direct comparison https://i.imgur.com/OqSwVJo.png
It’s much more accessible, especially for people with small to normal sized hands; all 6 thumb keys on each side are comfortable and convenient (but the back corner thumb key does require the extra tall keycap, so it can be pressed without running into the key in front of it).
See https://geekhack.org/index.php?topic=62848 for extended analysis.