SP is working on dye-subbing DSA PBT for the LCARS GB:
Sounds like waiting is the general consensus, and I've come around to this view myself. I have contacted Massdrop and I'll look forward to hearing whether they'll be content waiting along with us for the SP tooling updates. I'll post here when I have a reply.
SP is also sending me samples of the two dyesublimation printing methods (in-house vs screenprint), and I'll pose hi-res images here when they arrive. While we're waiting on the DSA tooling updates, we might as well proceed in nailing down the other final manufacturing details and finalizing the mock-ups with the new PBT colors the Pantone addition (which I'll work on soon).
Thanks everybody! More soon.
Valid opinions all.
I for one favor sticking to the ideas for this set that originally grew out of our discussions in this thread though, rather than switching things up just because it would mean moving to the ordering phase sooner. I feel like this should be a project of passion about doing something unusual that is as faithful as possible to the TNG aesthetic, without making any compromises. This what fan-run, enthusiast projects are all about, and what makes them special. We as a community can be more patient than a commercial enterprise, because we don't have any particular quarterly bottom lines to meet, and all the labor is free. 
It seems like the important things for staying faithful to the vision are: crisply rendered SWISS 911 legends, flat rounded-rectangles in the LCARS style as much as possible (i.e., DSA), and accurate colors. I'm going to keep working with SP to nail down final engineering details towards that end. I truly think you guys are going to like what they are working on for us. (I'll have photo samples soon to show you exactly what I mean.)
As soon as I have updated mock-ups, price tiers, and a more precise timeline from them I'll of course post here. It may take a few weeks, but I think they're proving to be weeks well spent. After all the back-and-forth previously, I'm a little reticent to prepare and post mock-ups again until SP can promise me that they'll be something they can actually make. 
SP is literally working hand-in-hand with us to bring their tooling into place faster than originally planned to accomodate DSA dyesub—just to enable a GH GB. This is a cool thing.
However the ETA until SP finishing their testing/tooling is unknown. Soon
TM.
On a semi related side note, weren't the Cyrillic caps that Cherry made, double shots caps then pad printed? So the latin alphabet (a,b,c, etc) are doubleshot and then the Cyrllic characters (Russian language letters) are pad printed.
