"So what's left? What material would you suggest they could use?" Type III Hard Anodized Aluminum, not the thinner, weaker Type II they apparently used. Also,

"So what's left? What material would you suggest they could use?" Type III Hard Anodized Aluminum, not the thinner, weaker Type II they apparently used. Also, a little more texture on the back would have disguised scratches better. I carried this HA III flashlight on my keychain for years with surprising little wear, given that it's constantly scraping against keys, key rings, and other metal tools. http://www.arcflashlight.com/arc-aaa.shtml http://www.arcflashlight.com/arc-aaa.shtml