I suspect they face different technical challenges than makers of wood guitars do, due to the Big Finish of fusing the whole thing together in one solid piece. With wood guitars you get to perfect everything and then slowly, carefully fit the parts together, but I think there's a big leap of faith with these Emeralds, the big vacuum-seal fingers-crossed deep-breath plunge.
Or.... perhaps it's QC problems, now that they've ramped up production so insanely. QC is tough. My guitars aren't perfect, with little squiggles around the fretboard here and there and a couple of off frets, but nothing serious.
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