So I finally got a long enough allen wrench to open the unit. As promised, here is the thermal analysis.
This is the main PCB:
I connected the unit to a 33 ohm dummy load and let it drive it at nearly max volume, outputting 5 volts RMS. Here is the thermal image:
The two red squares in the middle right are the AKM DAC chips. As you see from the red color, they are barely warmer than room temp.
The hottest spots are in white. There is a vertical array on the bottom right which are the output transistors for the headphone stage. The only other hot spot is in top left which is the XMOS USB controller.
I zoomed in on the XMOS:
As you see, it is just 33 degrees C.
The design from thermal point of view is excellent with nothing remotely being stressed. I get worried when temps approach 60 degrees C.
Just to be darn sure, I will cook the board with a blower next and report back on that.
For now, I also inspected the soldering. The headphone connector is soldered well as are the other through-hole components. The general soldering is not first class with some parts crooked, and a bit of solder splatter here and there. I would give it a B or B+. Nothing jumps out as reliability issue although mine is an early unit and may have been assembled differently than the units you all have.