What edge exactly do you think causes this?
There is two bumps that holds the silicon o-ring in place inside the bezel, one on the out side of the bezel that is associated with screw threads, and the other is from the inside towards the centre where the beam comes out through the lense, the inside one is a bit more protruding than it should, thus it is blocking a tiny bit of the beams outer spill border, and the sharper (less well made) the 90 degree edge of that protrusion is (like in my sample) the sharper and brighter the outer lighting circle is being.
It needs to be handcrafted, it won't entirely go a way but i think it can be reduced so much, it needs craving with patient and precision, the cleaner the handy work the better the result, i plan to buy a fine knife sharpener and sort it out slowly, i think it is going to be an easy task, hopefully..
Your replacement sample seems OK, that means better edge (it is a lottery and i think they picked up a good replacement sample for you), it is a grate light to buy, i'm very happy with mine, although that circle caused me to dissemble the head and i am a OCD patient, i cleaned a couple dust particles from the reflector on the way with ear cotton pickers gently, but couple of them wasn't dust and ended up having two faint scratches on my reflector, but it is fine (those LEDs are usually combined with orange peel reflectors), plus for some reason it is throwing farther after the scratches, for real i don't know why!! :laughing:
ATB, it's a great light.. I love mine.