Highly unlikely that it's a design flaw in any sense other than they designed something they apparently cannot build in quantity to acceptable quality levels.
It's one thing to pass an engine test with jeweler's sample prototype parts that are in the middle of tolerance and far better than they have to be, it's quite another to pass that test with the worst part that still meets specs.
The elephant in the room here is a confluence of several key factors mostly related to or mandated by regulations:
- Bearings aren't allowed to have lead
- Clearances must be pushed as tiny as as possible to allow the usage of the thinnest oils for CAFE.
- CAFE requires a highly power dense engine with tremendous unit loading and complexity.
- Complexity creates many, many more lubricated surfaces with with slightly different speed/load profiles
- The increasing use of engine oil as a hydraulic control fluid
Watching the teardowns of these Toyota 3.4L turbo engines, I just shake my head at incredibly complex they are. They make a Porsche engineer blush.
While I think modern TGDI engines are capable of some incredible performance and are a major advance in tech, I would never consider buying one that had only been in production a year or two. An engine that complex will take many years of warranty data and early life failures to allow them to refine and finish developing what the original product launch schedule did not allow.