Wow sooooo much has happened in technology in 11 years
I will tell you how simple it is. If you have the original figure, you bring it to a moulder (there are heaps in Hong Kong). They will usually charge between 5-10k AUD for a full mould for average toy. They will usually use this 3D scanning machine before moulding to create all the pieces. For ones that a slightly off, they will use the computer to recreate the mould. When its exactly as they need it. Give it a few hours, mould is made.
The price of the mould then depends on how many you want to make. A mould will usually make 10k pieces. If you are selling mass retail and will continue to use the mould then i suspect it will be more. The Devastator mould would cost Takara between 60-70k AUD but I am sure they will continue to use it for the next 10 years
Hence why all the henkeis are being reissued easily.
It's a piece of cake in all honesty.
In 2000, no google, facebook, smartphones, broadband home access, tablets... you get the drift!
