I recently had two of my best Lipo hard packs look to have expanded already. I have an Associated 5000/40C and a Orion 5000/45C hard packs, both are just 1 yr old. I do not abuse these packs, charge them as recommended and have Lipo protection ESC. I only use these packs for racing, 17.5 on-road. They have not been used more than 25 charges each.

Why would they look to have expanded already.

In contrast I have Orion 3200 ( purchased in 6/2006)' Orion 3400 and Orion 3800 ( purchased in 2008 and 2009) all hard packs and charged with over 100 charges each if not more and no problems.

Did the chemical makeup of the Lipo change and reduce the reliability with these higher rated packs or is there another problem?