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@Velocio
Just heard back. Certainly it's a defect that is affecting some of the caps but there's the question of what to do about it since they were made in Italy and the factory has shut down for the summer and no-one is there.
We can definitely make sure that any second batch has more attention spent to ensure that the elastic is adequately secured, but for the existing caps the volunteer effort to re-secure the elastic is probably the best thing for a quick resolution.
If any caps have serious defects beyond the elastic then I still have a couple that I can use to replace those.