I agree with Redguy. Why do the knife makers even use torx screws when phillips or flat head would work fine.
Because, theoretically speaking, Torx screws
should be a better solution for very small screw sizes when you want to make sure the screw gets tight enough not to loosen and fall out. This is due, in part, to Torx screws requiring little-to-no insertion pressure. All the force can be axial.
You think Torx screws are a problem in this scenario? Heh. I'd wager slotted screws would be worse, and Philips screws worse yet.
And why not hex screws? I hardly ever see those on a knife.
That's a good question. Same advantage as Torx (no insertion force required) and both English and metric hex wrenches are more commonly available.
I dunno. Maybe manufacturers think Torx screws look better?
In the end, I suspect the problems with Torx screws/drivers isn't the technology, but the tools and how they're used. A poor driver is a poor driver, regardless of whether it's Torx, hex, Philips or slotted. And a tiny screw that's been well-Loctite'd in place is going to be difficult to move, regardless the driver type.
Speaking of the quality of Torx drivers: The Home Depots near me had General brand, not WIHA, as some here have found at HD. The HD guy said the General brand Torx drivers were very good. I hope he was right.