Also, rigorously tested designs. R&D to the quality standards of other industries. (A wish, yet making them prohibitively expensive so unrealistic)
Design Failure Modes and Effects Analysis (DFMEA) is a standard part of any modern Product Development activity...
IF properly implemented as part of the early PD process (esp Design Brief stage!) it should not lead to excessive development costs vs unexpected catastrophic failures or even just recalls. However I agree unless volume is shared with the military, unit costs are likely to be much higher... and of course the military would be unlikely to allow the release of the same model onto the civilian market!
Quite a good FMEA summary here:
http://effectivefmeas.com/uploads/Failure_Mode_and_Effects_Analysis__FMEA__for_publication.pdf
Let me stress I am NOT a rebreather diver, but interested in these systems from a design and engineering POV.
According to a study by Dr Andrew Fock 'Killing them Softly':
With the caveat that they are “best guess numbers,” Fock concluded that rebreather diving is likely five to 10 times as risky as open circuit scuba diving, accounting for about four to five deaths per 100,000 dives, compared to about 0.4 to 0.5 deaths per 100,000 dives for open circuit scuba. This makes rebreather diving more risky than sky diving at .99/100k, but far less risky than base-jumping at 43 deaths/100k.
He found that there was no difference in fatality rates among manual or electronic units, or specific brands of rebreathers; accidents were roughly proportional to market share. Fock also pointed out that while the data suggests that deeper dives carry greater risks, a large number of rebreather fatalities occur in shallow depths within the recreational envelope.
As far as the causes or “triggers” that precipitated accidents, Fock concluded that the source of most problems was the human-machine interface, or so-called “pilot error,” involving assembly and pre-dive preparation, maintenance, training, and high risk behaviours that include ignoring checklists, carrying insufficient bailout and diving beyond one’s limits. “The question,” posed Fock,” is whether the risk can best be mitigated by training (reinforced by dive culture), or engineering out potential problems, or both.”
Rebreather diving: ‘Killing Them Softly’ | DIVER magazine
Currently, one of the biggest safety issues surrounding rebreathers is the fact that divers become complacent and don’t rigorously adhere to a pre-dive checklist in assembling and preparing their unit for diving as they (presumably) learned in class, and also neglect required post-dive maintenance. (Some experienced rebreather divers don’t follow checklists either.) Even worse, some divers choose to dive knowing that there are problems with their unit such as a faulty sensor or small leaks.
Creating A Safety Culture | DIVER magazine
So will creating new expensive high-end fully integrated 'fly by wire' rebreather technologies for the recreational dive market make the situation better or worse... if the diver feels they can then rely 100% on it?