They're not making irons (or anything for that matter) as good as they used to. I think they are made to go bad after a time so the manufacturers can stay in business :-) I think someone on the QB commented on the fact that quilters use irons way more than normal wear and tear so that may be the problem also. I know I've bought more than my share of irons... Right now I have Continental Platinum dry iron and a Rowenta Pressure Iron and Steamer--they both work great -- keeping my fingers crossed.