Ok, so I gave in to my OCD and went tonight to exchange my 2nd phone because of the semi loose volume button. While waiting, I tested every demo unit there. ALL of them had loose volume buttons to some degree - either the top or the bottom or both - except for one - I believe I looked at about 10 phones.
After this i was like, damn figuring i wouldnt get a new one without this tiny, but annoying issue.. but I held on and waited.. and waited till finally it was my turn, to the same guy who exchanged my phone just yesterday. Felt like a dumbass for doing it.. "uh gimme a new one - one of my buttons kinda moves around a bit" ..but I did it anyway.. guy was super nice, said no problems, out comes the "mystery" black box and guess what?
The new phone is tight on all buttons, no jiggles or wiggles! Score! So yeah, a phone with no loose buttons is possible, but given that MANY have it, its gonna be tough, I think I got lucky. But if it bothers you, go in and exchange 🙂