I think that you're making some assumptions that may not be valid. We don't know if the mag drop problem is limited to new guns. The gun has been in production for only a few months, so there is no reason to believe that the process or the specs have changed.
The "old" mags that came with my gun were dropping and I assume that the "new" mags would drop if not modified by S&W, so that suggests that the unmodified dimensions of both sets of mags are inadequate. S&W sent me a replacement mag catch that I installed. It did not fix the problem, so I assume that its dimensions are the same as my old mag catch.
Based on the data that I have, it appears that the new and old mag catches and mags are inadequate as manufactured. The only dimension change that made any difference was made by hand to the new mags that S&W sent to me.
I think that the problem is that the high pressure and snappy recoil of the .40 cal cartridge pushes this design to its limits and the difference between holding and dropping a mag is tiny and within the manufacturing design tolerances. I also suspect that S&W did not account for enough frame flex in setting the tolerances for the .40 frames and mags.
I have already modified my old mags with a center punch, so I can't compare the unmodified dimensions to the modified dimensions. I also don't have calipers. However, I do have four mags that work now, so I'm happy.
This does pose a problem for potential purchasers. There is no indication at this point that S&W has changed the design specs of the guns or mags so any.40 on the shelf could be a mag dropper. Until S&W announces that a fix has been implemented, no one will know what they are buying. If S&W announces a fix, then they will need to issue a recall, and they haven't done that.
Disappointing. Expected more from S&W. But I love my Shield as long as the mags stay in the gun.