I'm glad I'm not Mrs. Cheapo, because my husband is insisting on metal ductwork for the house which is the most expensive way to go for your HVAC (Heating Ventilation Air Conditioning) ductwork. My husband, the typical Swede, is so quality driven that he absolutely insists upon it.
From what I've learned, there are a few good reasons. We talked to several geothermal, HVAC consultants and took a couple of classes where they have said the same thing - Metal ducts are better. Metal ductwork lasts longer, is easier to clean, doesn't get particle buildup as easily as flex duct and the air flows better (less possibility for restricted airflow, which causes A/C inefficiency!). A/C usage and inefficiency accounts for a lot of Texan's house bills, so this is pretty darn important. You must insulate the metal ducts on the exterior to keep it from sweating if it's cool air or losing its temperature if it's heat. The only disadvantage I can see besides the expense, is that there have been cases where sound travels through the metal ducts to other parts of the house. There are solutions to fix this (duct liners), but I don't know what that does to the efficiency of the ducts (which will defeat the purpose of the metal ducts!).
The alternative has been to get flexduct (the most common in new homes) or fiberglass ducts (made with a rigid fiberglass duct board). The advantage is that it's way cheaper and already insulated. The problem that occurs is that flexduct bends, restricting airflow and being a lot more inefficient. They can also bust open (some guy found a little rat's family home in one once!EWWWWWW) if little critters can get in, and they are difficult to clean. 
Also, you will want to clean your ducts periodically, as there is always a danger of getting fiberglass particles, mold or dust in the ductwork. You do NOT want to breath fiberglass, as that is super dangerous to your lungs, which is why you always need a mask when putting in batt (fiberglass) insulation. With metal ducts, it is easier to clean very thoroughly with a brush. Another tip is that if you are sealing your ducts, always use MASTIC tape not DUCT tape, as mastic tape is better quality and does not wear out as easily as duct tape.
Metal ductwork will cost us about $4,000-5,000 more than using flexduct or fiberglass. But again, my husband says it's worth it! (*sigh*). I guess we're going to have to wait a little longer to get another car :-).
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The revolutionary product
Hello,
I agree with you either way, especially the part where your concerned about getting debris in your duct system and having to breath it. BUT, what if I told you there is a product thats available in some areas and will be available across the country very soon, that will keep your duct system virtually clean of all debris, and better yet will help keep your whole house clean of all types of dust. pet dander, hair, all kinds of particles?
And to top it off even better yet, with this system who save on an average of 17-23 percent on energy costs. Sounds too good? Well it's out there, if your interested I will get into more detail and a wesite you can go to so you can judge for yourself.
Thanks for your time,
Al Milano
There is another choice - mini ducts
Mini duct systems like Hi-Velocity (www.hi-velocity.com) and others give you a lot of advantages too. No dust or dirt build up, no need to clean them, even and healthy distribution of air. It may not satisfy the Swedish husband in quite the same way as a metal duct, but it's probably worth a look.