Nice to see someone (Christine) sticking their head above the parapet.
The old TARS lasted forever because they were more durable (and thus heavier). I also had one (an Expedition 3/4 length model) for over 15 years, before I stupidly 'upgraded' to a lighter Prolite 3. Since then I've been through the P3 and two Prolites; the most recent was bought autumn 2012, so this is NOT an early product run problem; it had at most three months' 'realtime' use on it before it delaminated.
Anybody familiar with the old petrol-tank-in-the-car-boot story?
This is not user error. It's quite simple. Thermarest suck up warranty replacements from people actually using these mats because they make more money out of not addressing the durability problem. Rather, they sell lots and lots of lightweight mats to people who don't use them enough for the problem to occur. My own feeling is that the cutouts are too big; there just isn't enough surface area left to bond to inside the mat. Resolve the problem, the mat gets heavier and thus it doesn't sell.
It's not just Thermarest, they're all at it. I had a POE mat that lasted 2 1/2 weeks before internal seams ripped out in two places. The UL apologists will now say it's my fault. Yeah, yeah, and she was asking for it dressed like that, y'honour.
There is an easy solution. It's called a Multimat Expedition Summit XL CCF mat.