I agree that there can be additional defects in glass which create distortions and inconsistencies, but fundamentally you get problems like this whenever you look through any piece of glass of appreciable thickness at angles far from the surface normal. Assuming there is a PVB interlayer, it should have an index of refraction very close to that of the glass and not contribute any additional problems.
I talked to the service manager at the SC about this and he said that some windshields did in fact have varying thickness problems creating regional distortions and had to be replaced, but he could see that mine did not. I'm skeptical that there are any windshields that do not have the basic problem of multiple images in the vertical axis. The physics of it just make sense, and other cars with very sloped windshields also experience the same problem. I can even see the issue in the Model S loaner I have, but the spacing of the images is much tighter and so it is not very bothersome. My guess would be that this windshield has less slope, is thinner, and I sit lower in the car so I don't end up looking through the glass at such a grazing angle.
I don't doubt that some people don't notice or aren't bothered by it, but that can be explainable by their height (eye position, higher = more grazing gaze of windshield = worse), sunglasses (polarization could attenuate certain reflections), and visual acuity (poor eyesight at a distance = lower contrast = harder to see additional images that are less bright or distinguish them from the primary image)
Once I get our car back from the SC in a week or so (fingers crossed), I'll try to take some HDR photos in the dark using a horizontal laser line to show exactly what spacings the images are forming at.
If anyone in the Bay Area thinks their MX doesn't have this problem, I would love to take a look, eat my words, and pursue getting a replacement windshield for my car
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Actually, I don't believe it's a design flaw, but rather due to manufacturing difficulties. Why else is the problem intermittent, some folks clearly have ghost-free windshields.
It's hard to make a large pane of glass smooth and consistent. It's even harder to add additional layers, while keeping that same consistency. My WAG is that the problem is with the layers not being bonded together well enough. Maybe the glass hadn't cured long enough or maybe the glass was subjected to stresses during manufacturing. Whatever it is, I'm sure they'll sort it out. Remember, this is also the first windshields coming from a new line in Lima, Peru. They too can have new-line issues.