This isn’t a question, just some information that may be helpful.
First, this has nothing to do with ardupilot/emlid but is relevant because of its failure mode if it happens while flying.
This week I had an SD card crack and then overheat to the point that the solder holding the SD card support melted and released the holder. Subsequent Google searches showed that this is not an uncommon problem on Pi hardware.
I was already dubious about flying with an SD card that has no mechanical locking.
Its a pity that Rasberry Pis do not come with onboard eMMC (like BeagleBoards do)
I’m planning to investigate USB booting as a mitigation.