Unfortunately all of the earpads are designed that way, which makes the fact that
Sony UK charge over £350+ for each earpad even more absurd.
My specific issue was that one earpad had a weird curve at the front area, and the that the left and right earpads were also different thicknesses too.
As I explained to Sony customer service, ordinarily I wouldn't care about such QC tolerances, but with a £1500 pair of luxury premium headphones, the quality control expectation is naturally higher.
Here's an image of the issue, the same ones I sent to the Sony engineers who decided this did not constitute as a defect...
Ironically even my new pair don't have perfectly matching earpads, but they're not as wildly varying as above, which for a hand stitched product I can accept.