Overall build quality is not very good, and I haven't even used the device that much. Makes me laugh a little, thinking of when people always said that the GP2X F-100 and F-200 had such a bad build quality. Pandora is much worse.
This is not an excuse, but I worked in industries making packaging in plastics and please know that it is extremely difficult to make something durable that does not crack everywhere. At least, it needs experience and knowledge, and people who know how to design the plastic pieces to make them very strong. There are always dozens of people working on this kind of issues in companies that produce millions of product, to ensure that you get close to zero defects on the actual case.
I don't think that anyone in the OP team has such knowledge and they unfortunately have to learn some as they go.
Indeed, we used the wrong company, we know this now.
We used the wrong PCB company too, again, a lesson learnt.
I doubt there are many companies like OP who get it all right, right away. It seems every successful business man you speak to has early tales of companies like DSW and CircuitCo.
It's just a baptism of fire we had to go though.
However - I hope that the iControlpad and now the Pandora 1Ghz shows that we have moved on.
The iControlpad case does not crack, actually a lot of people mention about how ridiculously rock solid it is - that's because we used a company which makes medical instruments and diving equipment to make it - but it cost a fortune - something we could never have afforded back in 2008.
However, with GC successfully making the Pandora PCB and plans moving ahead for an iCP2 and eventually a Pandora2 with cases made in Europe, I think we can assure you the quality will be near perfect on future products - it might not appear to be an issue which is near our top priority, but I assure you, behind the scenes, it is.