I guess I didn't make it very clear, but my question concerns the actual molds themselves, and the resulting texture design, not the application of the dye.
Each handle scale mold is comprised of multiple cavities, six, eight or even more, with the cavities connected by gates which allow the hot plastic to flow filling all cavities.
Each cavity in the steel mold is individually cut by die makers. Originally, it was done using pantographs, but later done using CNC machines which more closely replicated each cavity. Still, there were slight differences from one cavity to the next.
Break one apart and you may find a cavity number molded into the back of the handle scale.
After dyeing and assembly, the scales were individually glazed on a buffing wheel by hand and eye, thus more variance. Later, this was done using robotics and became more consistant, at least within the same production setup.
Every time a new setup was required (new production run, changed or dressed buffing wheel or other parts), the machine setup tech had to readjust the robot program. Thus more slight variances.
