I am increasingly convinced that star drive/double square/torx head fasteners are a communist plot designed to infuriate me and break my spirit.
I stripped out, probably the 50th torx fastener in my life time on a, not inexpensive, knife, earlier today. The long and short is, particularly small torx screws (T10 and below) strip with alarming regularity compared to hex/Allen, square head, and especially a good wide and deep slotted head.
Part of this is the bits have a tendency to break, because lots of torque, small surface area. But also the screws themselves are often not properly milled/cast around the bit opening. The tapered nature of the Torx head only exacerbates stripping compared to Phillips, by producing the same camming out effect common when Phillip's strip, but applying it over more, but smaller, surfaces, amplifying the problem.
In short, Torx sucks. And the gun/knife industry has come to rely on it far too much. I'll be grinding a flat slot into a Torx fastener later, with my Dremel. Something I've done far too many times.
Why did this shit standard ever become a thing? The only "benefit" is that the Torx drive doesn't have to be "timed" due to the symmetry of the head. I'd fucking trade that for a fastener that doesn't strip if you look at it wrong any damned day of the week.
I'm going to start buying slotted machine screws to replace every fucking Torx fastener I own.