How many bike and component manufactures are there really?
While there are a few more than “10”, composite frame and component builders that supply the majority of the industry probably number less than 10. I would bet there are 4-5 “main” suppliers right now who will work on various companies products.
Are we all getting parts from the same two factories in taiwan and they are just sitting back and laughing at us for talking about differences in quality?
As mentioned, not the same 2 factories, but most is made in a small amount of places. They are not sitting back and laughing, because not all parts are made equally, with the same product quality standards, etc. Most bike/component companies who really want to differentiate themselves via quality either have people who work directly at or with the factories in Asia. This way, they can work on quality (many have migrated to doing their own engineering instead of waiting for things to be done by the manufacturers), keep up their own QA programs, etc. This is why you see things like failure rates MUCH lower on some products (i.e. Cervelo, FSA, etc.) - because they are much stronger as designed and inspected by the company - not the manufacturing company.
Is anyone really looking out for us as far as quality goes?
Not really. At least in my position with my previous employer, I was speaking with all the engineering groups I could in the industry trying to determine if they could better engineer products themselves than relying upon the manufacturers. Unfortunately, I haven’t worked there in almost a year, so I don’t think there is anyone regularly checking on the engineering/manufacturing quality of frames. Their are some very basic standards that most companies will manufacturer to, but as far as I know, there isn’t any voted upon industry “standard”.
The various bike manufacturers have to rely upon their own quality inspection - in this day and age when new companies are popping up (thanks to open molds), and widespread media coverage (ST and the global electronic media craze), one bad failure could REALLY hurt any company with a bad reputation.
Is there anything wrong with getting these second-tier knock-off parts if they really do come from the same factory?
Again, it depends upon whom you are comparing these “knock off” parts with. If you compare them to that 2nd tier of bike/component companies who really do not have any of their own engineering/product designers, then I would say go for it. There is not necessarily any difference.
However, if you are comparing to those bike/component manufacturers known to have exceptional engineering, quality, and testing regiments - then yes, there is the possibility of purchasing lesser quality goods (as I have yet to see superior engineering within a product from any of the Asian manufacturers compared to those who have been doing their own engineering i.e. Trek, Cervelo, Zipp, FSA, etc.). Asian engineering is good, but it is still easier for them to throw people (number of engineers) at a problem. While many are U.S. trained, they simply have not (traditionally) equated to the companies with more experienced engineers and those who understand how to do advanced engineering (which utilizes many tools).
Personally I could care less about paying an extra grand for a name badge
There is typically not a $1k difference between frames being sold from an open mold. Most of those frames will probably have a couple hundred dollar difference - $1k occurs between frames from an open mold and those from a better engineered/private mold. Thus, you really aren’t comparing frames equally.
~ Craig Preston