Yeah, there's really not a better place for either the bump stop or crumple zone. But mounting the two directly together makes you wonder what they were thinking. Seems Ford could have done better by making the bump stop mount indirect to the crumple zone like SDHQ fabbed. I sure as hell wouldn't be trying to sue Ford or expect them to fix it under warranty though.
Ya, they do things based on cost and as long as it any failures that happen fall between their requirements its a go. I bet that during the manufacture process for the frame it would cost more to make dies that would punch the holes in different places so they make it uniform side to side... suppliers charge so much extra for things as simple as adding a bend or a staggered hole thats different side to side... As for suing Ford thats a very difficult road to go down unless there is a injury or death...