Like in my last post, the Tag-Connect technology is still patented for about another 10 years. What I’m doing is legally questionable but ethically not.
Since backups are important, I decided to design a version that can be sent to a normal PCB fab like OSH Park. Tolerancing the 1mm holes was the biggest worry but thankfully it turned out ok. Going a little bit tight turned out to be a benefit since it helped keep things super aligned. Since 2x3 1.27mm headers are hard to come by, I also used this as an opportunity to do my first flex PCB design and develop a standardized pinout I can use across all my future boards.