It looks like we may need to go through this again though this time may not be nearly as difficult to research yet will probably be harder to get a result.
In the original paper I wrote for this, I documented how this failure could occur and expressed our recall should be like the Cadillac recall and all PPS mats should be replaced. As you know, this was not the case. An active PPS fault needed to be occurring for a full replacement. If there was no fault, GM would put the reinforcing tape on the existing mat and call it good.
The problem we are seeing is that many of these "tape only fixes" are failing at or just past the 1 year warranty period of the recall repair. It is my hypothesis that these mats were already "damaged" when the tape was applied. By damaged I mean the mat 3D matrix of sensors had already started to tear but that the tear was not big enough to break the printed circuit that causes the fault. Once the mat is damaged in this way though, use of the seat WILL allow the tear to lengthen until it does eventually result in a PPS mat failure. The "tape fix", I believe, would not prevent this, only lengthen the time it takes to happen.
GM cannot tell if a mat is damaged unless the fault is active OR to tear apart the mat and inspect the 3D matrix within it. Of course doing the latter would render the mat unusable so only the active PPS mat fault method was used. It is my belief that ANY car that got only the "tape fix" should be recalled again and have a new mat installed and that, moving forward, the recall solution repair should only be replacing the existing mat, whether or not the PPS error is active or not, with a new mat.
So please, ANYONE who has taken their car in without the airbag light being on to have the PPS mat recall performed but who then later had the airbag light come on again only to find out their PPS mat has now failed, please go to the NHTSA complaint site (link below) and register a complaint. I will start going through that database next week to collect complaint counts. Thank you.