The Exped Downmat 9 (our sleeping mat) has a foam(?) insert that provides a barrier between the down inside and the air nozzles used to to inflate it. Over the course of the last week the insert for both mats broke loose. This means that when we deflate them if we're not careful they either spew down everywhere or get completely clogged and won't deflate at all until you blow the airway clear. In addition to this, a new problem cropped up when we were making camp yesterday. The mats have six air 'cells' rather than one large airspace. The division between two of the cells broke on one of the mats so it now has 4 normal sized cells and one double sized cell that makes the mat completely uneven and impossible to lay on without rolling off. Lastly, the mat which still has six cells recently started suffering from a slow leak I cannot locate to patch.
When we were testing our gear before we left one of our mats failed with the down spewing issue. I had my reservations about using them but the reps at Exped assured me that it was a manufacturing defect that they see very rarely. We received a replacement and had no further troubles. After just over 70 days on the road both of our mats are nearly unusable.
I've just sent an email to Exped hoping that they can help in some way. Until Exped changes the way their Downmats are constructed I must strongly recommend against their use on any 'Exped'ition. I'm loathe to report this as they are incredibly comfortable and we took very good care of them. We'll suffer for a few more days until we hear back from Exped; hopefully they'll 'exped'ite us a shipment of some other, more capable sleeping mat.