But nothing is perfect and you are never gonna be happy if you are always picky about stuff.
Posted via Android Central App on the HTC One M8
There's picky and there's sloppy assembly. Every phone I've owned has been PERFECT, assembled to a precise spec. There's always some bad bundled app or a battery sucker to turn off, but a phone should arrive in PERFECT condition to stand any chance at all of lasting even two years. I think OP is reasonable to expect no manufacturing defects in a new device, in a refurb you must be willing to forgive a little glue or some misalignment from reassembly...but new should look and feel NEW.
Godforbid but if my Flex needs repairs I wouldn't mind a looser volume button or similar cosmetic symptom of reassembly, if it came out of the box like that I'd consider if the problem was worth taking it in for exchange.