This looks like solid plastic on this one, But what ever it is it need fixing.
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To give some perspective in size and space - how would you even be able to hit that inside edge on the bottom of the headset?! Its way thinner than you would imagine on my macro image.
Contra foam theory: it has to be translucent for the IR sensors and it would be more expensive than just regular plastic.
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Not sure, stronger housing for beta units could explain that too.
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Black plastic is often grey on a break. So until we have a legit cross section we can’t presume foam core board.
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Bad batch of plastic used it happens. Worked for Polycon that makes pretty much most cars bumpers.
The non enviromentally friendly plastic was better quality.
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True but the so to speak beta m2’s we know had the optic sensor to sense face. The m2 production units had this removed.
Devils advocate time (please not be offended) . 
I actually tapped my headset with wand whilst adjusting it on my head playing Beat Saber. Therefore I didn’t see anything. It’s now showing crack. Can I RMA my headset please?
I am considering cutting some black duct tape to about 1/2 inch wide and putting it all around the whole seam to prevent this happening, kinda getting a little paranoid.
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The problem is simply quality of plastic & lack of thickness/support on vulnerable points.
I would like to know what plastic they are using.
It’s clearly too brittle for sharp angles & corners like on the pimax.
These headsets are cracking on the corners from light use.
What happens when we actually do hit them with controllers or drop them?
Also, these cracks are VERY hard to see.
I suspect if more people have a really close look, there will be a lot more
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I have treated my 5k very gentally,it certainly hasn’t be whacked or bashed and can clearly see the crack is apperearing through being forced apart by something inside or bad casing joints
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Ok maybe I am wrong BUT it looks like they all crack on the front half of the case, this leads me to believe the front half of the case is to small and to tight when fitted.
Think they need to make the front half of the case a fraction bigger. 
slightly slackened screws might help if the plastic is very inflexible
Never used the vive wands yet. Just sitting in my simulator.
But even if someone did hit the headset - do you know how many times I hit my vive and rift hard? Not a single crack. Hell I slammed a vive wand into my concrete ceiling (damn vanishing realms) and the painted ceiling took more damage than the wand.
Why did pimax use such thin and brittle plastic combined with such sharp edges in the design? Why did they have better mockups with rounded edges? Just to save money?! Or did their supplier screw things up?
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As you can see the casing on mine is trying to come apart all along the bottom and cracked at the end. It now has a white stress mark in the plastic where its being forced. The usb type c plug on the bottom is also not central in the case,also lots of creaking when you hold the headset. @anon74848233 this was one of the 1st 100 produced i believe if that helps.
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If you look at the pictures there are no screws.
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I was thinking about the 4 screws holding the shells together
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From looking at it it looks like the front is forced over the back part (via a locking lip ) and bonded.But the casting of front casing is to small and buckleing,the creaking from the casing and rippled effect of plastic along the hmd would support this theory
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Ho I see , 
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Exactly this 
20 F`n things
My point was would Pimax RMA if someone posted that it was shoddy design/craftmanship as the cause of cracking via accidental damage? As you point out, these wouldn’t happen on rival headsets due to their design.
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