re: Schottky - I'm not sure how many people use external power, but I know that I often have it attached because I am reprogramming a circuit in place, or programming a circuit that uses more than 100/500ma. I also know some of our commercial users have a need for it because they upgrade in place. Regarding them blowing - if they blow they saved you from blowing out the Attiny in many cases! So for power users they act as a one time cheap safety device. Because of this I don't see any disadvantage having them, the voltage drop is well in spec, when they blow out something else would have likely blown otherwise, and they cost about 1 cent, so I'll concede they may not be as necessary as I originally thought, but there certainly doesn't seem to be an advantage to removing them.
re: Fuse -I expected everyone to demand a fuse, I have to date only had two people request one - they are over 10 cents each so unless people speak up they probably are not one the feature list at this point.
re:Microsd footprint - I see no reason not to put footprints for everything possible on the bottom - microsd makes sense because it doesn't need any other components. If there is room I'll put it on - that space is tight even for traces. Definitely a shield regardless
I still debate the snap off usb plug, but agree with the footprint for a micro usb on the bottom (lets avoid a mini vs micro debate - I prefer mini, but micro is far cheaper, doesn't require holes int he board which we don't have room for, and not at end of life) - at the very least the traces will be done in a way that the plug can be cut off with no ill effects.
Expanding on going to parallel pins - I'm also trying to make it so with a set of risers you can plug in two Digispark shields and have them use different sets of pins!
Thanks everyone for contributing!