I made me a pressure-sensitive IR pen the other day and it works quite well, but after only light use only on very smooth white boards, the tip of the LED is flattened and abraded. It doesn't even require a lot of force to light up the LED (about 50g), but I suppose it gets repetitive shocks on its tip when writing normally, and drawing long lines a bit fast really sandpapers it, even on smooth surfaces.
I'm thinking of glueing something at the tip of the led, such as a chip of rounded glass from an old miniature lightbulb, but if I remember correctly, glass reflects IRs, so it may not be such a good idea. Or I could glue a piece of some other, harder material.
How do you guys cope with LED abrasion? It took me a couple of hours to make this particular pen, and it's really nice and reliable, so I hate to see it waste away so fast.