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I would return it while you still can. If it was a used device I would say try to clean gunk and grunge around the button with rubbing alcohol and cotton buds but a new device should not need that.
Maybe run the end of a pin around the button edges in case it's purely a mechanical catching on the frame ?
You could of course sit and press buttons a few thousand times to see if it gets better or worse, if you have the patience. I read somewhere that kobo buttons get less stiff when used a lot
As for design flaw, Google may have images of opened mechanisms to inspect, rather then open up your new one and maybe affect warranty
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