Are there other brands of regulators failing because of this even when the owner follows the recommended service interval? Incompetent service people notwithstanding, I would think the part would get replaced during a service before failing, no?
It's not so much "failure" as it is the poppet seat acquiring a groove ("taking a set") that then allows the second stage to freeflow a little. When that happens, a typical diver may indeed think, "my reg is failing", or "my reg had lousy service. Look - it's freeflowing already!"
If you service things yourself, you know that it's a five minute re-tune, by adding 1/24th of a turn on the orifice, and bingo! Freeflow gone.
But now much nicer to have a seat that hardly takes a set, and never seems to need tuning in between service intervals! That's what seat saver regs allow.
The way shops avoid this problem with ordinary brands and most divers, is by handing you a reg that is tuned to the top of the allowable cracking effort. It breathes stiffly (if you are trained to feel the difference), and to me that is just wrong! But most divers don't know the difference.
The advantage that tuning stiff offers the shop is that as the poppet seat takes a set, the cracking effort drops bit by bit, and the reg gets easier to breathe. But it doesn't take enough of a set in one year to freeflow before the next service is due.
I'd rather have a reg that breathes soft and easy (bottom of the cracking effort range), with a mechanism that allows the seat to stay as good as new, for not one, but two or even three years.
As discussed above, we used to teach divers to take the pressure off the seat by inserting the "key", or pressing and locking the purge button "in" during storage, on those regs that have the feature. But that is uncommon knowledge, these days.
If a diver comes in asking to have his reg tuned "really light", we talk about the possibility that it may freeflow a little 3 months from now. We talk about using the adjustment knob to increase spring tension and (maybe) save the dive before he/she brings it back for tuning. And we definitely talk about ways to take pressure off the seat with the purge button during storage. But it is the RARE diver that has a specific cracking effort request.