Personally I am also seriously considering dropping the material altogether, be either Tan or Clear Ultra. Aside from some very specific customers who want their products in said material (mostly because for lighting kits I guess), I see no longer much reason to continue with it.
I mostly make ship model kits and I've been using Smooth Detail for small, detailed parts like secondary and AA guns and fittings in 1/600 and 1/700 scales, but with the sudden mass rejection and unnotified thickness changes for the material, I may just drop it altogether as there's not much difference with Versatile Plastic anyways. Smooth Versatile has an infinitely better finish, and if I have to design a barrel that's 1 mm thick otherwise it would not print, instead of what I could do before with Smooth Detail, I may as well have it print in Versatile than Tan.
I understand Shapeways' problem with the discontinuation of their previous printers and materials offering the Smooth Detail option, but to me it seems everybody agrees that the new choice backfired spectacularly. Notwithstanding the massive misinformation hiccup to shop owners and customers alike about the spec changes, but this is not the place for that particular rant. The point now is, that investment has been made and is probably here to stay. Now the problem is the material itself as is far from being equal to the previous choice.
Obviously we cannot expect Shapeways to ditch their investment in new printers just because the material is not up to expectations, nor even the one of old (although that should be reason enough). Instead, I suggest they focus on finding a material that's compatible with the machines they are now running but can get closer to the original Smooth Detail specifications, but even if that would not be possible, then at least fix the material finish issues. Because what I've seen posted so far in this thread is most definitely not an acceptable compromise for a commercial solution, even if it's cheaper than the older one.
The alternative is what some people (myself included) have already stated, ditching the material altogether as not competitive nor satisfactory enough for customers. Some others have found themselves confronted with the horrible choice between reworking most of their models (speaking mainly of miniature shop owners) or just restart from scratch, if the blow to morale does not make them leave altogether for a different market. And they would probably feel justified in doing so.
I don't know how that would hit economically speaking, but with the issues at hand I can hardly see how the investment in this new Tan and Clear Ultra can even pay for itself in the long run, if a portion of shop owners is willing to ditch the material altogether instead of going through the hassle of multiple back and forth with angry customers asking for refunds and multiple products being rejected (sometimes more than once, ask me how I know) to rework to new specs. It would be easier sometimes to just build a new one on par with current specs.
As I said, since you Shapeways asked for suggestion and feedback, then probably looking for a more refined material to use with the same printers would be a more feasible solution. You would not even have to replace Tan and Clear Ultra, just add another option that could either print finer details, or have a really good, nice and shiny smooth finish, as this should have had from the beginning. Ideally both, but this is a world of compromises.
I understand this is also not an easy solution, but you asked us for feedback and these are my 2 cents on the matter. Because the current state of affairs is far from ideal and worsening the longer it is dragged on.
CH