I had this discussion with Klim when I stopped in for a visit on my way to Utah not to long ago. The problem is demand. Once the demand for your product gets so high there is no place in the USA capable of keeping up with demand. My understanding is Gore-Tex and Klim looked pretty hard at making a factory large enough in the USA to just keep up with Klim's demand. After looking at cost to build, taxes, labor, etc., a Valdez parka would more than double in price.
If your not happy with the quality of Klim gear it's to bad cause your out of options. It doesn't get any better. If gear could be made better than Klim makes it they would be the ones to do so. I was impressed with the knowledge of their design team. I mean these guys know everything about every material available to mankind, and if there is any chance anything would work better than what they currently use, they have already built it and tested it. I had no idea how much R&D is going on all over the world testing different products as they come available. They know everything from threads to number of stitches you can afford to have per inch before you decrease the long term durability of a fabric. Yes they make money, but they do everything they do with our comfort and safety in mind. They take a lot of heat from guys on this forum, but it's rarely deserved. We hear so much about the bad experiences, but they currently have less than 1% of their products coming back for warranty claims. (Yes that includes gloves) That's unheard of in the outdoor clothing industry. It also speaks volumes as to just how much gear they actually sell worldwide.