CY is right, most problems are caused by a leaking battery.
First off, we will fix the light for you regardless. Just send me an email.
Some of the leaking cells could be because it is easier to overtighten the head. This could be literally squeezing the 'juice' out of the cell. The Arc-AAA should not take a lot of force to turn on.
Another contributing factor to a cell leaking is draining it dead. The Arc-AAA is really good at that. Now, I too like to get every last bit out each battery I buy, we just need to buy good brands and watch the cell. If it leaks, clean it up right away and the Arc-AAA will be no worse for wear.
And finally, some cells just leak even with good care. If that happens, it usually affects the negative contact area in the bottom of the battery tube. That can be cleaned with a wire brush, sandpaper on the end of a pencil eraser, steel wool, etc. Sometimes people either don't know their battery leaked or they couldn't clean it. In either case, this is by far the number one cause for lights sent in for service. Symtoms include flickering, intermittant startup, dim output and complete non-function.
Even though the battery is the culprit, we still clean the pack out for you free of charge.
Now, even though battery leakage is the number one problem, there are other things that can go wrong. For those cases, our offer to repair the light still stands.
Peter