Hi, I am new to this forum. Is there any update on this project? I have managed several plastic injection molding projects at the company I work for, can help with questions in that area. Biggest problem I've come across with trying to re-use molds is the molding technology can vary from vendor to vendor, moving one mold to another company could be a huge headache and cost almost as much $$ as just making a new set of molds.
You should consider having the vendor that molded the imagin parts quote you 500 sets of controller parts in black. Keep in mind the circuitry will have to be a different vendor, and then assembly you will have to do or contract another company.
Good Luck, I am interested in one if you succeed.