Sorry, I don't know the specifics regarding how the cards were manufactured or created. Where there were corrections made to the traces, those certainly appeared to be hand-drawn.
I know of at least one early version of the Geneve that did not have a gate array and if I recall correctly, was not as robust a card. The Geneve we know today had had at least two iterations if we include the trace corrections. I don't know how many board runs were made though if I were to guess I would say at least three based on the color of the mask, the trace correction, and the brittle nature of some cards. Eric Bray is one person who might know the answers to some of these questions, as he knew/knows Lou. (As an aside, there are at least two runs of HFDCC cards, notable by the colors of the board, the quality of the traces, and the QIC-02 circuit differences)
As for Cecure reproducing cards I recall discussions but little came of it. The TI-CARES deal gave Cecure a shot in the arm, However, while both the TI and Myarc business kept Cecure busy it certainly was not a sustainable, long-term model. It was always my impression that more money was spent supporting the TI community than came into the business, whether through long hours of phone tech support via their 800 number or trying to drum up new business from a dwindling group of people who demanded more service for less money. Other non-TI efforts to make money to keep the TI business afloat took time and resources away from the very TI business that was slowly dissolving as people left for other computers. By the time I took ownership of Myarc repairs, the situation was pretty rocky. The rest is, well, history.