So much crap from both sides on this. Apple handled it poorly, yes, but this guy has some bullcrap from his side, too.
Utter crap. Apple runs a specific diagnostic to test for the Nvidia failure. Even if you get no video but starts up, it still runs from a thumbdrive and dumps a logfile to it, which you read to determine the results of the test. If the Macbook Pro doesn't POST, then you CANNOT TEST IT! Furthermore, you CANNOT definitively say that it was the Nvidia GPU! Any number of failures on the logic board can prevent booting. Oh, it was likely that it was the Nvidia GPU, sure, but you CANNOT know that, and if it wasn't the Nvidia GPU, then guess who foots the bill? Not Nvidia. Testing it would require shipping the board to a facility where the old one could be desoldered and a new one soldered on. Not exactly the kind of thing you can do at an Apple Store. Granted, it didn't help that Apple sent some very non-technical chunkheads who couldn't seem to explain that to the judge.
I heard this idiocy a number of times when I used to fix Macs for a living. I wanted to shank them with a blackstick every time I heard it. GET OVER YOURSELF. Everything fails. Expensive things, cheap things, it all fails eventually. Sometimes it fails within a month. You could call that defective. Over three years? Um, no. There was a problem, but "defective" implies that there was a problem with it from the start. Not knowing for sure if this was the Nvidia GPU (as it wasn't even POSTing), there's no way of knowing if it was "defective" or failed due to any other potential means. The amount of money you spent on it has nothing to do with that.
Again, he has no possible way of knowing that. If it doesn't boot at all, then there's no way of knowing for sure if the problem is the Nvidia GPU.
ABSOLUTE GARBAGE! This is a 100% LIE. Why in the HELL would Apple be handing out defective boards, especially if Nvidia was footing the bill for the defect? No. Once this issue was discovered, the boards were NOT replaced with defective ones. At worst, he would've received a refurbished board with a non-defective GPU in it. I don't know where he came up with this hairy load, but it's utterly wrong.
Apple's biggest mistake was sending the weenies they did. Sending in someone with more technical knowledge than this guy (who doesn't seem to know as much as he thinks) would've probably won them the small claims suit.