I would have to agree with lampeDépêche... TMK, there isn't another 1xAA light in the same weight class as the Mini AA that represents a material improvement in reliability and/or durability. If for some reason you were dissatisfied with the Mini AA, you could check out the EagleTac D25A Mini, which is a very similar light with a (removable) clip and a stainless steel bezel. It's 0.77 ounces empty, and with the clip removed it should come close to matching your Mini AA's 0.7 oz weight. The D25A's stainless bezel
might provide a tad bit more protection for the lens than the Mini AA
if the light was dropped and landed bezel down on a rock or pavement... but that is probably not statistically relevant in the grand scheme of things. And since your Mini AA is neutral/warm (Foursevens doesn't make lights with NW emitters any longer) and the D25A Mini is only available in CW, that may be a trade you're understandably not willing to make.
Revisiting some of the previously proposed options...
The L3 Illumination L10 twisty that markr6 mentioned is 0.73 ounces empty, it's a very nice light with a high-CRI option, and it has the advantage of adding a moonlight mode* if that's desirable... but as he said, their ability to withstand a drop has a less-than-stellar track record.
I think to add more robustness, you are looking for dual springs in the body tube and/or potted electronics. The Zebralight H52W gets you the latter, but comes in at 1.1 ounces empty. I see that you've considered this option carefully, but I would just throw some more weight (ha ha) in that direction... it's a NW emitter with a great tint, it has very efficient circuitry -- on the order of twice as efficient as the Mini ML (High = 108 lumens, Mini AA runs for 1.3 hours, and ZL H52W runs for 3 hours) -- and moonlight modes to preserve battery life (
*maybe you could carry fewer batteries to compensate for the weight gain?), and it represents a significant durability/reliability improvement over the aforementioned lights. You can leave the headband at home if you wish; I've read that some folks use it with the (removable) clip, allowing you to attach it to your shirt or backpack strap instead of strapping it to your head.
The Peak El Capitan aluminum pocket version is ~1.63 oz with a
14500 battery, and represents an even more robust package than the Zebralight H52W for equivalent weight... but I've read that it's not all that bright on non-lithium-Ion AA cells, and the QTC UI is not for everyone.
Obviously my vote is for the Zebralight
but if you're happy with the Mini AA, you're doing fine with your current light.