Gonna bump this to ask, does this only happen when the console is docked? (Yeah i could go trough 6 pages and what not but pshhhh)
No plan to do that anytime soon because i enjoy it in handheld mode. Just curious.
It could be related to blocking the airflow leaving it on a soft surface while powered on. Which I have done a few times (leaving it on the couch while typing on GBAtemp or chatting etc) before realizing "oh shit, there are air vents under there", but it was never for very long at a time and the game was always paused or in a menu so it's not like it was running something super demanding. And honestly it doesn't get very hot at all in handheld mode, compared to when docked. And when docked those air vents are more or less blocked anyway, so it's way more likely to have been caused by the dock. I would have noticed if I picked the Switch up after leaving it on the couch and it was really hot, and that didn't happen, so I doubt that's the cause (at least in my case)
I'm sure the Switch will get really hot if left on a bed or similar running BotW (without pausing the game), but realistically you're gonna pause the game when you put the console down, and even if you didn't, the dock really seems like a worst case scenario, there's hardly any room behind the air vents when docked, plus it's clocked higher when docked.
Once I get back from my vacation in about 5 weeks time, I'm gonna return it, which gives them about a month to repair it before Splatoon 2 comes out.
Once I get it back, I'm gonna take the back off the dock. Hopefully it doesn't happen again after that.
For now I'm gonna stick to mostly using it in handheld mode. Of course that's not always possible (for example if I want to play multiplayer), but considering I'm sending it in, I don't want to take apart the dock just yet.
I was doubtful that it was caused by heat originally, but after having it happen to me, I'm almost sure it has to be caused by heat. Only two people have handled the Switch except me and while one of them might have a habit of grasping controllers in a death grip, he only tried it out for a few seconds and I watched him the entire time and it didn't seem like he was holding it excessively hard (at least not hard enough to bend it), and I've been really careful with it myself.
So it's not really likely that it's been bent by force.