First off id like to say again ive had no issues thus far with my flask.
A few things:
1) The down button on mine does protrude out further. As all other owners have confirmed this, i feel it fair to assume this was a design choice to help users differentiate between the two buttons. I like this, it makes my life easier.
2) The USB port was designed to be floating. Think about it: if you knock or drop your flask whilst charging, that port will flex and move instead of bending or breaking off the cable in the charge port like a fixed connection would be susceptible to That would suck. It would also help if you did have any kind of venting from batts or the chip itself. Good, no one likes venting
3) my battery threading is good. Not great or buttery smooth, but they have definitely been breaking in nicely. I feel that the vaseline trick would solve 90% of the thread issues ppl are experiencing. All threads not steel based tend to need a bit of "warming up" so to speak.
I hope the chip issues are resolved on Rev3 DNA40s
As i said my chip has performed basically flawlessly for about 4 days of constant and i mean constant Temp Protection mode use. I havent touched any of my other mods. I like using it that much.
Im sorry for all the folks whove had QC issues. If i were you, i would contact Vapor Flask directly and i am willing to bet the will answer any questions and solve any problems, up to sending out a replacement unit. Members here have already confirmed that they got fully new replacement units with ease. Mos reputable modders will go above and beyond to satisfy any and all customer complaints.
After all, we are the ones who pay their income
Happy vaping.