what prevented Dyson from building it better?
Presumably he thought it was good enough as it was. Clearly the cleaners were robust enough to make the initial sales, and from there the attraction grew, so sales boomed. And on it went. The original Dyson cleaners were subject to countless modifications as the years progressed, and as for the hose, it must have cost the company tens of thousands in replacements sent under warranty.
The thin, brittle plastic was used from 1993 until around 2005 if not later, when it was finally changed to something softer for the main parts of the cleaner. The effects of the sun on a Dyson cleaner can be catastrophic.