Forget the rotation, it still doesn't explain why a contact patch on two tyres was there and flat spotted when I didn't do an emergency stops. Just doesn't make sense. This was in a stock 2003 Focus hatchback. Why weren't Falken interested in seeing the tyres? Didn't want to admit to a faulty product? It makes you wonder.
I can't speak for your exact situation, but wear is never covered for sports tires. The fact that they weren't rotated gives even more grounds they were improperly installed and/or maintained.
Ever consider the tires wore out? 10k on just the fronts would easily do a set of 200utg tires in. If people get less than 20k (more like 15k) out of 615+s even rotated regularly, that's less than 10k of the tire's life on the front. Between being fwd and your front tires doing the most work during braking, they wear twice as fast as the rears. Hence the frequent rotation. Once you get a little uneven wear, tires really go quick.
IME defective tire symptoms include bulging, cracking or tread separation. What you're describing is wear and 10,000 miles on the front of a fwd car is a lot for aggressive compounds.
Not an expert just my experience and 2¢
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