Its a curious thing...
Ultimate have been selling the 'Airtube' monitor for a year now as an alternative to the full electrical version, in talking through the two systems to customers pros and cons, in most cases customers still choose the electrical version because they want the best sound delivery, even though it is clear for all to see the electrical version with wires, drivers and soldering joints contained within the plug it is a more fragile product over the airtube with no moving parts contained within the plug.
Our cable problem was one of stipping/fraying or in some cases brittle cables (oily skin caused a reaction to the cable) as we were supplied 3 different types of bad cables.
Cables detatching from the ear plug are not caused by the wrong cable but a consequence of use and imposed construction constraints. How to overcome this?
User Education:
Well education is one way in all too many cases poor handling of the plugs and cables is a direct cause of the failure.
Re-routing Cables or Moving the Cable Exit:
Re-routing cables or re-positioning the exit point of the cable - Place the exit point in the centre of the plug or route (loop) the cable out over the ear (behind the pinner) will increase the likiehood of discomfort from a close fitting helmet - the very comfort issue many are seeking to overcome from helmet mounted speakers.
For me the best solution for on-bike use is the airtube with the cable exit at the Tragus, its what I use, its cheaper to buy and yet for every ten sets of monitors we sell, customers order nine electrical monitors to every one airtube monitor. In the fortunate position I am in by having both airtube and electrical I have a choice, using the airtubes on the bike where the 'quality' of sound is less critical and the electrical monitor is used off the bike as my earphones of choice, travelling (airplanes, trains) sitting at home listening to music, anywhere where quality of sound coupled with excellent sound isolation is a requirement. To the point where my Bose in-ear phones and Sennheiser over the ear headphones are now redundant.
Most suppliers have ducked this one by removing choice from the customer, you want a monitor you can have one and one only, they know music-wise and comfort-wise they are not up there, but they can make them in their restricted agent base (without having to hand the sale over to a 3rd party and lose profit) and they are more robust so that's 'good enough' then.
At Ultimate we have spent a great deal of time and money getting the product that the customer demands right, its a continual development cycle which yes you the customer may well have to get involved with, product eveolution, everyone who actually designs and produces their own products does this - or we just remove choice, concentrate solely on profit and everyone is happy right
A heck of a lot of electrical monitors have been sold over the years, the vast majority have provided the quality experience those customers desired and paid for, but every failure is a problem that we need to overcome and that's what the company will strive to do.