Alright. After sleeping on it, I have a theory. Bear with me, as I don't have an iPhone 4 yet (it's on its way here from SoCallong story). Tell me what you guys think.
On the iPhone, I presume there is some sort of light, stylistic anodization or coating on the steel parts. I could (definitely) be wrong, but usually a brushed or muted texture on steel indicates some sort of coating or treatment to the steel's outside. I don't have an iPhone 4 yet, so I can't test my theory. Could someone tell me if this is true?
Either way, such a coating would prevent us from "completing the circuit" between what are supposed to be two separate antennas. If there is a manufacturing defect in the coating, you would surely complete the circuit with physical contact (or any other conductive contact). If this is the case, then it is a manufacturing defect, not a design flawthough I will admit that the design enables this defect. This would also explain why people can't reproduce the issue; and some can only reproduce the issue with a few dropped bars but no dropped service.
I'm hoping it is a defect; the design is beautiful, and changing it would prove to be a debacle for both the consumers and Apple.
If I'm correct, Apple need only strengthen the process used on the antennas (be it a light anodization or whatever else it is) and issue a general recall on broken iPhone 4s. The recalled stock can be used to make available refurbished phones, and everyone wins.