on plugs, a slight taper to the stem, make it easier to get them snug in smaller holes in your rockwork and if you move frags around the rack a lot. round, square and hex shaped heads are my fave.
on the discs(round or square) I like thin and since they are being printed maybe make a grid or indentation system on the bottom to make them snap cleanly, and you could still use a saw to cut custom shapes out of it if need be.
For the ones that are four connected together just make sure the spacing between the four legs matches egg crate like the ecotech plugs.
as for PLA, last I read on it this is what stood out....
"Since PLA is made using a ring-opening condensation polymerization, the only contaminants that are released from melting PLA will likely be those in the bulk lactide solution. Since that's ultimately derived from corn or cane sugar in a water-based fermentation, you are highly unlikely to find any toxic vapors or ingredients in PLA, even during heating and molding."