Would I return a new car if it had a scratch? No. Would I request they buff it out and return it if they refused? yes. Do I buy new cars? No. I buy certified pre owned cars because I dont collect cars. I use a car. And I know that an item i use is going to get damaged. So to safe money and weaken the blow of the first ding I buy used. Knives I collect. I buy a few to use, others dont get used at all. Those are the ones I really scrutinize. Because IMHO it sucks when you buy a brand new knife, never use it and then go to sell it yet lose more money than you normally would because you simply cant convince a second hand buyer that "thats just how they come".
I work for a company that makes large heavy equipment (dozers, end loaders, scrapers, excavators etc.). We know that in some parts of the world we have to deliver a product that has a perfect finish, as some of our customers want a perfect paint job, perfect ornamentation etc., even though we all know the very first time this machine is used it will be permanently blemished.
My analogy of the car was apropos, as a car and MOST knives are made to be used. You are buying tools that were made to be used, but your use is different than the manufacturer intends.
In the USA, my company knows that a large mining customer is not going to give two hunks of rat fur that there is a scratch on the dump-bed of a truck, or a blemish on a dozer blade tooth, it just does not matter or warrant any more attention to detail. However, we do strive to deliver a perfect product that will delight the customer.
You do absolutely deserve to be delighted with your purchases, and as I stated before you should try to get satisfaction if you find something wrong with your purchase.
I reiterate that, as you asked in your original post, you are too picky in that you are buying a tool that is to be used, and your complaint is that the knife is not perfect in every way.
Has the level of quality gone down since "the good old days"?
Absolutely not. Products are much higher in overall quality today than they were in the past, even the fairly recent past. What were your choices in, say, 1970? 1980?
There have been advances in design, materials, execution; we have 3d machined aluminum and titanium, super steels, ball bearing pivots.
As a collector, you might even be disappointed if the BOX were somehow not perfect, as that would potentially impact your resale.
You state that you do not want to have to convince a second hand buyer that "that's how they come", presumably because you want top dollar for your "collector knife".
Back to my car analogy. Early Corvettes were far from perfect. They had ripples in the bodies, poorly fitting panels, inferior paint and yet today those same qualities make them more valuable as a collectible in original condition in today's market.
If you are truly a collector, you will probably be much happier if you were to buy multi-thousand dollar custom knives than you ever will be buying $200 and $300 dollar knives that are really intended to be used.
Finally, I have either had exemplary luck in my purchases, or I am just not sensitive or able to detect flaw as you are able to, and that may be a large part of our differences.
I do understand your frustration though. My frustrations today are more oriented toward the service industries, where "blemished" products are rampant in my opinion.
I wish you much luck in your collecting, and I sincerely hope that you can find the knives that will make you most happy.
best
mqqn