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Very occasionally, I get a suit whose pips favor some zigzag lines. I got a “rocks” suit on one deck which was a grey color and did this! It looked like jagged boulders. Possibly this outcome should be slightly more common to increase variety.

I'm not sure (as I said it was created too long time ago) but I think I didn't like how zigzags looked. For my taste they were good for variety, but not as a frequent element.

I suppose mask shapes could also be varied more.

Are you talking about specifically pips here? I think they are too small to make their shapes matter (except maybe with aces, twos and threes). But Major Arcana and face cards I would add something like random blob shapes to portrait large non-round, not-rectangular objects (including figures).