Where's a scientist when you need one. Science should be able to explain it. I've heard some people here say that the metal can some times store energy from trauma it was exposed to previously and then suddenly release that energy, but then it would still have to be the users fault more than likely. I'm pretty sure the factory employees didn't go around busting up all the phones. And if I remember the process that they make these, there is no bending of the aluminum to get it to this shape, it's all milled out from a solid piece. Is that correct or is that just the laptops and iMacs?
I'm sorry, I just do not see how a metal would bend without outside force being applied to it, unless you guys are heating up your phones to make the aluminum so weak until it bends under it's weight.
This is my initial thought as well, but then I see stuff in these two posts from this very thread that points to the possibility that aluminum failure can indeed occur on its own. The fact that Apple decided to use low tensile strength aluminum in this phone and that the location of the bend in the phones I've seen seem to be around the obvious weak spot near the volume buttons both have me thinking that the bend may not necessarily be caused by the users.
Now don't flame me or the OP just yet on this one because Aluminium can actually spontaneously bend!
It all goes back to when the aluminium was smelted, extruded, annealed and if this process is not completed impeccably well, You get what is called "Snap Back" and this is when the aluminium try's to go back to it's natural state!
Even though this experience of aluminium bending is not the same as the OP's it show's that Aluminium can just bend without external forces!
A friend of ours had an extension built with one of the sides of the building being a wall of glass and the structure beams were made of aluminium! The problem occurred when two of the massive sheets of glass started to crack and shatter and it turned out that the aluminium beams were bending themselves thus breaking the glass! When the structural engineers came in and did a full report as to what caused the glass to break it was proved that the Aluminium was bending caused by the annealing process and it was caused by a difference in surface stresses pulling against each other! Ian thinks it was called Biaxial behaviour!
So i am not saying in any way what so ever this is what is happening to the select number of iPhone 5's that are reported to be bent! but it can happen.
Just an observation based on 20 plus years experience in the aviation industry, metal has memory, and it does not always react to a stress at the time the stress was applied. I guess that was technically two observations.
An overhaul of a landing gear assembly typically follows the path of tearing the assembly down to the component level or lower, performing visual and dimensional inspections, non destructive testing, and rejecting any components that fail the inspection criteria.
My team will occasionally have to do a tear down on a landing gear that was involved in an incident, for example a hard landing. When a hard landing occurs the components in the landing gear assembly may be subjected to stresses they were not designed for. The effects of these stresses are not always immediate, in other words the metal can essentially store the energy of the stress, only to release it at a latter time. To deal with this we may need to quarantine certain components for a period of time, usually 6 months or more. We then compare the pre quarantine visual, dimensional and NDT findings to the post quarantine findings and look for variance. Typically we do not find a variance, but occasionally a component that was within tolerance pre quarantine will be out of tolerance post quarantine
So it is conceivable that the bending is related due to stresses imposed in the body, but not the face plate, during manufacture. I'm not saying this is what happened, only that its a possibility.