JJH, who would do the outside inspection???
Legally, your opening yourself up, if not returned to the factory, for final inspection and repair, yes the design could and probably is flawed. A key to allow your firearm to work is a bad concept, especially if it is incorporated into the design of the piece. To those who like the concept, an outside lock is a lot better idea. If your trying to bring smith and wesson to it's senses, e-mail, write or call them.. " Don't send them back " absurd. There are'nt any certified revolver key lock safety experts out there other than the factory, and they are factory certified, not federalized, and would we trust any offered expert if they claimed it!!! Better yet, would the courts? Smith and Wesson is an forthright company and will fix it's failures.
Finally, how can the factory correct it's mistakes if not given the oppurtunity? When you try to produce what people want there is always a learning curve. An ultra light weight anything, has consequences. Usually more severe movement.S&W will correct this, I have no doubt.
Smith and Wesson is not the only manufacturer to have a problem with key lock safeties.
I've installed many aftermaket and older factory safeties on newer remington shotguns, that have the new key lock safety, because they engage while shooting.