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Has anyone encountered problems or mechanical faults with these headphones, specifically after daily use for a year (or equivalent)?

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Generally speaking, these are some tough, durable, and modular headphones that can have almost every piece replaced if broken. Many people are still using HD 650’s (launched 2003) or their ancestral HD 580 (1993) today, with just a pad replacement when they wear out and flatten over the years. Back before the HD 650 launch, sometimes the springs that make contact with the cable’s connecting pins could lose their tension if the cables were disconnected often; that’s much less likely after the HD 650 was released with stiffer and robust springs and also added to the HD 600 at that time. If YOU have a mechanical problem, please contact either Drop or Sennheiser’s customer support; it comes with a two year warranty!
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