wow. Mr. Tone, sounds like a thorough intervention.
Have you also tried a lithium battery with the same results? I don't understand all about the electronics involved, but I've been able to consistently see flickering with my AA zebralight when the battery is nearly depleted and I assume that it has something to do with voltage being stepped up to supply the led and the depleted battery not being able to keep up, and so the voltage stepping up in little pulses instead of a steady flow.
Maybe there is some critical variance in components that will let some of the lights pass QC while being unable to supply max power in some conditions, but it seems much more likely for it to be a moving part issue.
Can you replicate the problem with the tail cap off, bridging between the battery and the base with a penny or something?