I only recently picked up my first pair of Grado headphones and have had zero issues, but two general responses based on my experiences with different audio brands over the decades:
1) Boutique brands (like Grado) do a lot by hand and occasionally miss something.
2) Boutique brands (like Grado) are almost always great with customer service and support.
It used to be that manufacturers would describe things as being
hand-built as being some indicator of quality. I think they do this less now as the public has come to learn that, actually, machines are far better.
My European cans are all remarkable intricate designs. The most recent being the
Focal Azurys are very much in the school of moulded plastic but it is just remarkable how good it is, how detailed it all is, how fine the design is. I'm sure there are dedicated machines at the factory that press these various pieces together and then put the tiny little screws in, probably all at the same time. There is probably a human operating the machine, but the machine is doing the essential aligning and all that fine stuff. I also think probably it is all taking place in China or India but this final aspect is the least important issue for me.
I think that manufacturers like
Focal design their cans to be built by machines and they design the machines that build them at the same time. The cans could not be reliably assembled by humans.
Grados are built by hand and so they are designed to be built by hand. The design is extremely simple, I think a major reason for the captive cables is that it makes assembly simpler and for
Grado the time spent assembling each unit will be a major factor in price.
Things that are built by hand will be designed differently and actually, I think that people respond positively to this, even if they aren't thinking about this issue. My three
Grados actually appeal to non-audiophiles as objects in a way that none of my other cans do. People want to pick them up and hold them, maybe try them on. There is something about that wood and the way they are constructed that people just like.
My other activity in life that involves messing with equipment is bicycles and I see something similar with old hand-built steel framed bicycles. People just love them. Even if they have no knowledge about bicycles they gravitate towards them, they want to touch them, maybe sit on them. You know when you see one that it was built by someone, it has such a different vibe about it from a contemporary aluminium framed bicycle.
In truth, functionally, the manufacturing machines are better. They don't make mistakes, they are extremely accurate and my guess is that machine built headphones will, on average, be more reliable.
Everything says that I should want the machine built cans, but I want the hand-built ones.