I. Sums
The best we can do so far is to find infinitely many quadruples $(a,b,c,d)$ with distinct elements where the sum of the squares of any two is a square except for one. First consider the four smallest Euler bricks $(a,b,c)$ that are not necessarily primitive,
$$(44, 117, 240)\\
(85, \color{blue}{132}, \color{blue}{720})\\
(88, 234, 480)\\
(\color{blue}{132}, 351, \color{blue}{720})$$
Notice that a pair of bricks share two sides. This automatically gives the quadruple $(a,b,c,d)=(85,132,351,720)$,
$$85^2+132^2 = 157^2 \\ 85^2+351^2 \neq\, \square\quad \\ 85^2+720^2 = 725^2 \\ 132^2+351^2 = 375^2 \\ 132^2+720^2 = 732^2 \\ 351^2+720^2 = 801^2$$
There are infinitely many such quadruples. Saunderson's Euler brick parameterization used the condition of Pythagorean triples.
But Lenhart's parameterization instead used the condition $x^2+y^2=5z^2,\,$ thus,
$$(a,b,c) = \Big((x^2-z^2)(y^2-z^2),\; 4xyz^2,\; 2xz(y^2-z^2)\Big)$$
$$(a,b,c) = \Big((x^2-z^2)(y^2-z^2),\; 4xyz^2,\; 2yz(x^2-z^2)\Big)$$
Note that the second brick just swapped $(x,y)$ leaving only the third term changed. For example, let $(x,y,z) = (2,11,5)$. After removing some factors and signs,
$$(a,b,c) = (1008, 1100, 960)\\(a,b,c) = (1008, 1100, 1155)$$
Giving the quadruple,
$$(a,b,c,d) = (960, 1008, 1100, 1155)$$
There is a polynomial parameterization to $x^2+y^2=5z^2\,$ implying one for $(a,b,c,d)$ as well.
II. Differences
Incidentally, if we now wish differences instead of sums, then there are also infinitely many quadruples $(a,b,c,d)$. Again, only one difference is not a square. Example,
$$(a,b,c,d) = (975,\, 952,\, 1073,\, 1105)$$
therefore,
$$-\,975^2+952^2 \,\neq\,\square\quad\\-975^2+1073^2=448^2\\-975^2+1105^2 = 520^2\\-952^2+1073^2=495^2\\-952^2+1105^2=561^2\\-1073^2+1105^2=264^2$$
Like in the first section, $(a,b,c,d)$ can be expressed as polynomials. More details in this MSE post.