I have now gone through several Geminis that all eventually start getting cracks in the plastic that covers the hinges.
Strange; I use mine countless times every day, and it's survived a year without any apparent deterioration of the hinges. How are you treating yours??
The hinges (and associated cables &c) are always the weak point of any clamshell device. But the scale of your problem does make me wonder whether you're doing anything to exacerbate it.
(BTW, I think they said Cosmo Communicator will have a stronger hinge.)
As for waking-up time; mine has always taken a perceptible time for the screen to turn on after opening it, but it's usually around half a second; I don't think it's ever been more than a second or so. I don't know what causes the delay, so I can't suggest anythijng there.