Welcome aboard, and thank you for weighing in and explaining your take a little more on the above, Resolve.
I always enjoy listening to these live streams btw, and frequently take new ideas away from them,... whether you have on any guests or not. I'm sorry for the bad heatwave you guys have been dealin with as well. I've spent most of my adult years in warmer climes, so I'm somewhat used to it by now. But I know for folks who aren't, that it can be a difficult adjustment.
I understand that the subject of driver symmetry is a thorny one, which can present some special challenges to reviewers like yourself. For both the reasons you've stated above. And for other potential reasons as well. For starters, everything has to be working pretty much perfectly on your equipment just to ensure that both earpieces on the headphone are receiving the exact same signal amplitude at all frequencies. I would imagine that there are some ways of calibrating the rig to improve or refine its performance along these lines though.
There could also be issues related to the way a headphone interfaces or seals with a rig, that could potentially introduce measurement artifacts into one channel, but not the other. Averaging the response over multiple seatings (as you presently do) should help to mitigate the chances of that occurring though, I would think.
There are also alot of people who simply aren't that sensitive to, or interested in L/R imbalances as well. And mostly concerned with a headphone's tonal balance. I.e. the levels in the bass versus the levels in the treble or midrange, for example. Rather than the levels of the right vs. the left channels. This is probably more the case at the higher end of the price scale than at the lower end, I suspect.
There could also be some imbalances at certain frequencies in your own hearing, that might make you less sensitive to some kinds of imbalances in a headphone's response than others. And less than an ideal subjective judge of problems along these lines. I have more HF loss in my right ear, for example, than in my left. Which sometimes makes it a bit more difficult for me to judge when a headphone is favoring the right channel a bit more. So humans are not always the best gauges for these kinds of things.
And there are probably some other issues along a similar line that I haven't thought of, which could make it more difficult to accurately assess or measure a headphone's L/R balance.
Most of the headphones that I've used have audible imbalances though, of one kind or another. And it's often helpful to see where and how that's occurring a little better on some type of a graph, both to confirm or deny what I may be hearing (or think I'm hearing) in the headphones with my own ears. And to also correct or compensate for it, if necessary (and possible).
At the higher end of the price scale, these imbalances may be the result of quality control issues, as you suggest. So I understand where you're coming from when you say that you'd generally just return a pair of headphones for repair or replacement, when you encounter something like that in most of the headphones that you're reviewing... That makes perfect sense.
At the lower end of the price scale, it can be a (potentially correctable) flaw in the actual design of the headphones though. And not something which varies significantly from unit to unit. This seems to be a very common issue, for example, with alot of headphones that have single-sided cables that attach to only one earpiece. Which is more common among the lower-cost studio type headphones that I mostly use than in higher-end headphones (which typically have double-sided cables).
All of the halfway decent headphones that I've personally owned have been single-sided. This includes the AKG K553 Pro, AT M50x and Beyer DT-770. And they have all had noticeable imbalances in their drivers, of one kind or another. Which I believe are less the result of QC issues. And likely more related to their (single-sided) designs. The same has been true of most other headphones that I've also tried or used (but decided not to buy or keep) in the same or similar price ranges as the above units. I could rattle off a fairly long list of them to you, but it would include other popular lower-end headphones like the AKG K371, and AT M40x. And possibly also one or two of the Sennheisers.
Single-sided cables have unfortunately become kind of a de facto standard, especially for studio headphones. But also for alot of consumer headphones in the sub-$300 range. So they are difficult to avoid at this point. And it's something I've frankly never really liked that much or appreciated, even for my own "studio-ish" work. And if you decide to exclude all headphones with this type of design, it extremely limits the available options.
If you know what the imbalances are, then in many cases they can be corrected. Which can sometimes result in a
dramatic improvement in the headphone's stereo imaging performance! If there is just a slight difference in the overall volume between the two drivers, like on my 250-ohm DT-770's, then that's a fairly easy issue to fix. Because it can be done with just a simple left-right stereo balance control (if you happen to have one of those on your player, amp, or DAC... which many people do not!).
If the drivers have different imbalances at different frequencies though, then correcting the issue is more difficult, because it may require
separate EQs, or tonal balance adjustments for the two channels at different frequencies, which is more involved. If the headphones are easily reversible (like my previous AKG K553, and the Beyer DT-770), then there are some tests you can do with frequency sweeps and whatnot, to figure out a little better where the L/R discrepancies are in the frequency range, to better correct them. Imbalances in your own hearing also have to be taken into account when doing this though. And in-ear microphones could maybe also be helpful in looking at this.
If you can see the same problem in multiple reviews, with multiple units on different graphs though, then it's
potentially a bit easier to localize and correct. The problem with this is that many reviewers receive the
same review unit from a manufacturer. So you don't really get to see how this sort of problem can vary (or stay the same) from unit to unit.
This is a shortcoming in headphone reviews in general though, which potentially effects the reliability and accuracy of a reviewer's impressions and measurements across the board. And is not just related to the issue of a headphone's driver symmetry. So I don't really understand why you'd want to single this one particular aspect of a headphone's performance out for exclusion from a review, in this regard. And not some of the other aspects, such as the headphone's tonal balance, for example. Because there could potentially also be some differences in a headphone's sound and performance that varies from unit to unit in these other areas as well... No?
I agree with you that good driver symmetry
should just be a "pass/fail" kind of thing. But I've found that's not quite the way things work in reality at the lower end of the price scale. And the only way to really change that circumstance is to educate people on the issue, through reviews (and discussions like this one), so that the manufacturers do a better job of addressing the issue in their products at all price points. This is my opinion anyway.
A longish way of just sayin I mostly agree with Crin's take on this particular issue. But there ya go.
Hopefully some of this made a little sense.