Iain (post #20) hit one critical design feature that that has not been mentioned. The HP seat design. I didn’t follow some of the rest of the post, but the points about seat design is extremely important when talking about long term reliability.
The early Conshelf’s and Royal Aqua Master used a hard rubber seat. I used to service them a lot in the 70’s. When they worked, they were extremely reliable a lasted a long time. I have tried 40+ years old Conshelf that still lock the IP like no other regulator.
That wasn’t always the case while servicing a regulator back in the 70’s. Some of the rubber seats just didn’t work well and there has been more than one regulator that I had to try 2 or 3 seats before the IP held good enough to send it out the door.
I should add that IP gauges were not as common back then. We did not attached them to the QD hose… We didn’t have QD hoses. We had to attach them to a second 3/8” LP port if there was one. So IP checks were not done as often and a bit of IP creep was acceptable a probably very common.
Variations in the volcano orifice would have had a big effect, but the hard rubber seats were definitely not always reliable, but when they were, they would last for decades.
Fast forwarding to the late 80’s or maybe early 90’s. US divers (now Aqua Lung) went through a big research/ development project for the new seat material. I am not sure how long it took, but the new blue HP seat is a close to bullet proof as a seat can be.
I am not as familiar with the Mares line, but because their heritage/ roots of some of their first stages, the seat design in the MR-12 (and I think a few others) is interchangeable with US Divers/ Aqua Lung. Mares also went to a seat development program and they came out with what they call their “tri-material” seat. I have not used it, but my understanding is that it is just as reliable and long lasting.
Now you can also buy an aftermarket seat from Trident (and there are other sources) that will fit Aqua Lung and Mares. Some are now as reliable as the Aqua Lung seat, but AFAIK Aqua Lung seat was the best for a long time.
When I designed the Argonaut Kraken, I made a conscious decision to use the most common seat design available. The manufacturer (VDH) was not going to have the resources to source a new seat design and to be honest, why re-invent the wheel. My understanding is that Bryan (at VDH) now has a new supplier for very reliable seats, but the material science behind the seat synthetics is probably not a secret anymore.
I should add for the piston regulator fans (I used to be one). The seat in most piston regulators tend to be much thicker and they used to be just a solid chuck of Teflon (or similar).