I have to ask, given this is for me the worst pad I have ever slept on, how do you people who like it sleep? I've held off selling mine because I keep seeing people who insist they like it, and they are obviously not making that up, but I am just as obviously more uncomfortable on it than any other pad I have ever used.
My guess is this: given the edges of the rolls, the actual regular size pad width is about 17" or so inflated. So if you toss and turn, it's basically a formula for sea sickness if you have the pressure down far enough so you don't fall off the edges, which is almost impossible to not do when you roll over, since your body is that wide, at least, as you roll over, and if you have it hard, you are always falling off the edges as you turn. If you sleep on your back, or side, and don't move, and just pass out, in that position all night, this pad would in my opinion be close to heaven, and I could see why people like it if that's how they sleep.
So my guess is, people who like this pad do not toss and turn much, and are fairly heavy sleepers. Being a light or heavy sleeper would account for why some people find the noise maddening, and some don't. The noise is definitely there, it's this crinkling sound, but the clue is, if you don't move, it doesn't make noise, and even if you do, it's not that loud, but it is there. Hint, use ear plugs, it's not louder than they block, if this was my only issue with that pad I'd love it and swear by it, sadly that's not the case.
Re the noise, I would estimate it as probably 10x or so louder than a prolite or foam pad, in terms of actual decibels (correct me if I'm wrong, but I believe decibels are a logarithmic scale) , but of all the things I disliked about it, the noise was for me the least of the problems. Ie, if a prolite is 60 db, and a foam pad is 50, then a neoair is 70 db, just guessing, but that might be around the volumes, give or take 10 db in the range.
Re the original cause of concern, yes it's very thin, and feels very delicate. I was impressed by german tourist's experience of seam failure, that does not at all surprise me, I think thermarest is pushing the boundaries of what is practical with light materials and they are going to hit statistical failure rates far higher than say, their old green/tan series. It's the statistics that get you, if you have 2% failure, that means 98% don't, which is something the people who are in the 98% often fail to grasp. The x percent that fail sleep like cr@p the rest of their trip since the pad has zero value as a pad once flat, and then probably get something else for next time. The 98% are happy and swear it is great. This to me roughly accounts for the variance in user experiences, my guess is they are going just a bit too cheap/light in their production, and that's causing x percent to fail.