In any case I was referring moreso to the RROD issue on the Xbox with my first paragraph, especially since that was the most prolific issue and was indeed a symptom of more than just a switch in the solder used.
You can think of it two different ways that mean the same thing.
1. Microsoft and most electronics companies didn't design their electronics correctly with regards to lead-free solder. This include Nvidia, Sony, Toshiba, Samsung, LG, Sharp, Philips, etc. Once everyone was forced to use lead free solder in a relatively short period of time, there was a massive increase in the failure rate of electronics across the board. Some companies did relatively better with it than others. AMD, for example, did a better job than Nvidia, but even they had some early teething problems.
2. Basically none of the above would have happened if lead free solder hadn't been forced onto companies. Companies knew well the tolerances and behavior characteristics of leaded solder. Not so much with lead free solder. Even now most of the budget electronics companies continue to have problems with lead free solder when they didn't have those same problems with leaded solder.
Anyone that has worked in the salvage/recycling industry will be able to tell you about the massive influx of electronics when the industry was forced to lead-free solder.
So, could MS have designed the X360 better to accommodate lead free solder? Possibly, but as mentioned no one had a really firm grasp on all of the potential behavioral characteristics of lead free solder. And even now, cheap electronics manufacturers still can't reliably make electronics using it.
IMO, the forced switch to lead free solder was one of the costliest and most environmentally bad government mandated things ever to have been forced onto corporations and consumers. A better disposal and recycling policy would have been safer, less costly to consumers, and easier to implement. But you don't get a lot of political points doing that. It's much easier to get political points by pointing and saying Lead = Bad, even if the environmental impact from leaded solder in electronics was absolutely miniscule.
As to the PS3 versus X360? They all appear to be failing at the same rates. Just X360's that were going to fail would fail sooner due to the higher thermal stress (my launch 360 still works fine). PS3's on the other hand are failing later in life. If you use this forum as a microcosm of this. While you no longer see people with launch 360's failing (like mine), we've seen a large increase in launch PS3's failing due to the solder (hence reflow trick to get them working for a bit). Had both companies been able to use leaded solder, failure rates would likely have been right along the industry average pre-lead free solder.
Regards,
SB