Re: [skup] Smaller diameter pins?
There has been discussion (and research) on other materials for closing pins. Specifically that yellow Lolon cable that we use for our three ring systems. IIRC, the biggest problem was the threat of kinking/breaking, and the second biggest problem was that it wore out closing loops way too fast. Also, before the pin we use was around, the guy who invented the pin was taking bites of bridle and sticking that through his closing loops (which I think we're some elastic material).
I think the "standard" material for closing loops is not 550, but rather the same material for the white loops on our cutaway system. I'm not sure what the name is. Obviously a lot of people will replace it with 550 though, which works fine provided it is properly constructed.
The theory behind the frictional force, as mentioned above, doesn't strictly deal with surface area. It relies on two factors, the frictional coefficient and the normal force. The frictional coefficient is the interaction between two specfic materials, which we already acknowledged above in the form of the yellow cable, and changing this makes more problems to solve for now. The normal force in this case would be your pin tension, which is the simple fix for what you are looking for. If you want to decrease it, just lengthen your closing loops, and you've solved your problem without creating any more problems to solve.
All that said, I think this kind of out of the box thinking is what drives advancements in our gear, and discussion like this is positive for everyone. As our technology increases, there will be less room for innovation, but we will always have things to improve upon.