My understanding is that this is not a REAL Cochlear product. It is manufactured in Sweden, and Cochlear purchased the company or maybe just the product, and puts the Cochlear name on it. Maybe Jan knows more about this.
I am aware that injection molding...probably like the case is made, can leave small ridges on the final product when the two halves of the dies meet. This can become a weak point and because the BAHA vibrates, it can cause these lines to fracture. Ken's and my units have both fractured at the same point, and I believe it is along one of these lines that the fracture is happening. If you take the battery cover off, there are two small screw on either side of the battery holder. My cracks have been next to these screws. Ken believes they over torqued the screws during assembly...and he may be correct. Either way, both of these can be corrected easily.
The seal is another problem. I believe it is just a water proofing seal to keep sweat and other moisture out of the BAHA. It looks like the edges of the seal are glued to the back of the BAHA, and the seal begins to separate from the case. It needs to be re-engineered, or they need to hire 3M to get a new adhesive.
Little things, like using less force to tighten a screw, or polishing the raised manufacturing line from injection molding to be flat could solve the cracking problem.
I am looking on the bright side, and hoping they correct these issues.
James