Ok, so I build illuminated signs at my day job. Our 24V PSUs have short circuit, over temp, ground fault protection, etc. The frames are grounded, the sign materials are self extinguishing, all the bells and whistles. If you get a short, the worst case scenario is that some magic smoke tarnishes the sign and the lights go out. I STILL wouldn’t use that as an excuse to leave voltages separated by nothing but 0.3mm of PVC or use conductive glue for critical wires.
I think you’ve shown that the risk of catastrophic personal injury is relatively low, sure. But this rubs me the wrong way because the strategy seems to be finding a maximum acceptable risk instead of a minimum possible risk.
I ride experimental vehicles at unreasonable speeds because I’m wearing as much body armor as I can buy and I seek out empty roadways, and then my brain rewards me with the happy zoom zoom chemicals. What are you getting out of this pack design, reduced build time? Not worth it IMO