...As for the failure rate, you are either very unlucky or hard on your lights. In the early years ZL had some issues but, now a days they are pretty darn reliable. There are very little failure reports on here or other forums over the last bunch of years unlike some other brands. And, even if you do have an issue, ZL will fix any light for $15 even many years after the warranty...
All of my Zebras have seen extremely light use. All of them were preorders purchased directly from Zebralight's website. None of them were ever dropped and they have no scratches or other damage on their exteriors. For lights that used Lithium Ion batteries all cells were purchased directly from Zebralight, Illumn, or Mountain Electronics. No ultrafire cheapie batteries here.
SC51 - no issues
SC52 - Initially worked ok. However, now won't stay in turbo more than 20 seconds on a fresh 14500.
SC52w - Arrived defective. won't stay in turbo for more than 10 seconds or so on a fresh 14500. I suspect a bad ground connection where the driver meets the body tube.
SC580 - Arrived defective. When H2 is activated the light flashes briefly then turns off instead of going to H2. However, I still consider this acceptable as all other modes including H1 work fine.
SC600 - Arrived defective. Improperly wired switch caused the button to be activated when the switch was lightly brushed with a finger without being depressed or clicked. This was a known issue that affected many pre-order SC600s. Returned for warranty repair. Got it back from China 3 months later. The repaired light works perfectly. No issues since.
SC32w - Arrived defective. won't stay in turbo for more than 2 seconds on a fresh 16340 cell.
SC62w - Arrived defective. Initially wouldn't stay in turbo for more than 30 seconds on a fresh cell. After a few days of light use this had decreased to less than 5 seconds. Returned and replaced with a new SC62w
Second SC62w - Arrived defective. same issue as first SC62w though does manage to stay in turbo slightly longer (about 15 seconds).
SC5w - Worked great initially, but after less than a week of light use, output dimmed markedly and the light became useless. All modes still apparently work, but maximum output of the light is now about 1 lumen, with all other modes less than that. Either the driver or LED or both need to be replaced. The only batteries this light ever saw were Eneloop Pro.
SC63w - no issues.
SC600w III HI - no issues.
Most important thing for an EDC is that it must work when you turn it on. At this point, I'm rather hesitant to buy another Zebra, because of the rampant quality control issues I've experienced with them. I have more trust in a $6 budget light than in a typical Zebra.
When I compare to Zebra, the D4 seems absolutely amazing (much better UI, much higher max output, easily moddable, works when you turn it on every time, and if it ever did break I could probably open it up and repair it myself). In my opinion, the D4 and D1 are state-of-the-art, while my Zebras feel like "outdated tech".