I haven't checked this thread in awhile, but I also ordered the HD via the free case program. I got it sometime in the last couple of weeks, just haven't had a chance to open it and put it on yet (been using an iNcase Slider).
I don't know what all the fuss is about. While the buttons aren't as "easy" to push as without a case on there at all, they aren't hard to push. My case is bendable, pliable, feels like some kind of hardened rubber, not brittle at all, no signs of flash residue on the case...although I can see a little blip over where the injection came into the mold. I tap the top button, turns on/off, etc. I tap the volume buttons, turns up/down. Things work as they should. Sure I can tell I've got a case on over my buttons, but my buttons are protected so I'd say thats a fair trade-off. At least I don't need fingernails like with the iNcase.
Seems like a very durable, fine case. I never had the prior version so no point of comparison, but when compared to my Griffin Reveal, a Bumper or the iNcase Slider....seems just as good as any of the, and likely protects better than anything other than the iNcase. And even there, I'd say its a tie between the iNcase and the Pixel HD. While the iNcase is obviously hard plastic, the material of the PixelSkin HD is clearly very durable and likely 'chip proof.' I've dropped my iP4 while in the iNcase Slider and it rubbed off some of the matte finish and chipped it a bit. I doubt that would happen with the PixelSkin HD.
Seriously...maybe there was a bad batch out there? Mines just fine.