Thanks for the response. I did you the SparkFun template / Eagle library for the card. Any goobers in the outline are just the result of the PCB fab tolerances. I did check several of the raw PCBs against a teensy uMod. It seems that some of the routing tolerances on around the key are sloppy. Not all the the boards, the the one I use for a build was worse than others.
I think the edge chamfering is a good clue and makes sense. I had to do it manually as the board house I used wouldnt do it on this sized board.
Thanks for the data on your testing. Good to know that it went through through a lot of cycles. The power here is pretty small (on the scale of mA for an MCU)
I have new PCBs on the way for more builds and will look closely at what comes back from the fab house.