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If it's possible to re-thread incorrectly, then the design needs to be changed.
Interesting perspective, and I can see some merit in the argument. On the other hand, are there other common designs in scuba equipment, where it is possible to mis-assemble / misuse gear, with the consequence of malfunction and associated injury? And, if so, should all of those designs be changed? It is certainly possible to fail to enter correct data in your dive computer. And, if you do a dive to 80 feet on air, but your computer thinks you are diving 36%, could you conceivably be harmed? Should that computer design be changed? If so, there will be a whole lot of changing going on.
I think the Zeagle system is a very good one. And, I actually don't think the ripcord is technically difficult to rethread, just a bit tedious (not a criticism, just a personal observation), hence my lack of enthusiasm for 'testing' it. But, I also think a reasonably intelligent, reasonably facile person should be able to rethread it properly. However, I also agree it is not foolproof. And, as the signature of one regular ScubaBoard member indicates, 'Nothing is foolproof for a sufficiently talented fool.'
What we don't know from the available data is who was responsible for 'service' of the gear. We know that it (apparently) hadn't been serviced in 3 years, but we don't know who was responsible for that service three years ago. Was it the individual divers on the team? Was it a single member who had taken on the unofficial role of service technician (like an 'armorer' in some police departments - someone with an interest, possibly with aptitude, not necessarily with training)?
It is too easy to assign blame to inanimate 'equipment' (for failure) in a case like this, and obviates the need for evaluation of human performance, which is always challenging. As I suggested before, I think the evidence is consistent with (multiple levels of) human failure, whether it be in rethreading the BCDs, in making the dive knowing that the equipment was not in proper working order, or in overseeing the training exercise.