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Ugh, that's a lot :/
For a new Pixl - if you don't have enough ideas already: I really like the Wio terminal, because it has a color lcd with fast refresh rate.
On the flipside, the color LCD is of course a power hog. Any chance of a product with a replaceable display option? Low power sunlight visible and a regular-ish LCD? Something that fits in the case, so won't accidentally fall apart, but reasonably protected?
Another annoyance: It's interface options is kind of lacking, only one I2C is available on groove connectors. The other I2C is only accessible in the 40 pin Raspberry Pi compatible connector. That connector feels like they had no idea what pinout to use... Even with the battery chassis that adds 6 more groove connectors, the other I2C is not accessible :O
Yes, I'd be a bit concerned about the free tiers having been bitten by Travis once. But I think there's a real possibility of for instance only making these server-related ESP32 offerings available to Patreon supporters.
I really like the idea of more products, but as you say it's more work - also more stock and risk. I think if I felt there was really a gap in what I was offering (for example Wifi boards) I'd definitely go there though. With a few carefully made boards I can go a long way towards doing a lot of what people want.
Although for example I'd love to make a new Pixl board with the really nice 400x300 4 color st7301 displays we found and a case, but I have at least 500 Pixls in stock at the moment, which is £15,000 - and I'm less likely to sell those if there's a new, better board out there.