I have carried 5 AP's in my wallet for around 9 years now. At our peak we were at the parks around 40 days per year and feeding our AP's through the turnstiles on average about twice per day. My 2 older daughters would commonly carry them out of the sleeve and in there pockets while at WDW. In all that time, with all that abuse I have never once had to replace one.try doing that with an annual pass,I think you are all missing my piont a annual pass looks just like any other ticket and is on the same card stock.Maybe just maybe a card you would have for over a year that will be used many times over the year should be made of better material?
Given the 100% operation status with the mylar AP's that I have experienced over the 9 years worth of real world world torture testing I have put them through I fail to see a way that they need to improve the quality. They are supposed to go through a card reader and admit you to the park. Nothing more. If you need a status symbol to show regular guests that you are an AP holder and therefore better than them buy a t-shirt that reads "I am an AP holder! Bow down and worship me!"