Nobody was paid anything. I guess the wheel squeaked, and now there may be grease in return. I agree about more communication may have prevented this, however I felt like Jetboil had put down a hard line in the sand, and that their line was unreasonable and unacceptable.
I posted here looking for other what others had experienced, not for a flaming pitchfork mob. The fourth post said that they had experience and suggestions, but they never responded to my PM. But whatever the methods, the outcome was a dialog with the manufacturer. Let's take advantage of this and see if we can make forward progress without additional foment.
As far as the fin failures, I was told of their top notch quality control and that it was unlikely that any units could have left the factory with unbonded fins, but clearly mine did somehow, and it seems like others may have as well. I'd love to talk to their engineers to see what sort of solder/braze they use to affix the aluminum to the titanium and what surface prep they do. With the thermal coefficient of expansion of aluminum being nearly three times that of titanium, I wonder with temperature cycling the solder joint becomes weak? Not the case with mine as it failed on the first heating, but food for thought for the other failures.
Also, from the few photos on the web of the melted fins, there seems to be at least two failure modes. Like mine, where it seems like the fins weren't bonded or became unbonded - the entire unbonded fin has melted away and the adjacent well adhered fins are untouched. And some others where it looks like the fins are still bonded to the cup but the tips are burned/melted away. This failure mode seems more consistent with heating the cup without water or cooking somthing other than water at too high a heat which allowed the bottom of the cup to overheat. This would allow the parts of the aluminum fins furthest away from the heat sink of the bottom of the cup to burn away first. Interesting that I haven't seen any failures on aluminum systems where this failure mode would be just as likely as on Ti units.
I think using titanium fins may be cost prohibitive, or perhaps the low thermal conductivity of titanium would make the resulting flux ring inefficient. Again, talking to their engineers would be really interesting.
I really wasn't out to skewer anyone, however, and I'm a bit embarassed at how rabid this has become. I was just a bit miffed about how they were dealing with my problem so I reached out for some input. I got it. It worked. Let's see what comes of it.