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There's one thing these other small companies that you're probably used to dealing with have that OPT doesn't: surplus money.
I imagine the thinking basically went
OpenPandoraTeam: You're late! You were supposed to have had this done months ago!
Mould factory: yup, sorry. We're working to get it done as fast as we can.
OPT: Well the contract said you'd be done by now.
MF: You are correct. Since we're late, the contract is basically void. We'll put everything on hold and let the lawyers look it over and see what we need to do to compensate you. We should be able to resume again as soon as that's taken care of. Shouldn't take more than 18 months or so.
OPT: ... So how long do you need to finish?
Lawsuit isn't really an option, as it's basically impossible to sue a Chinese company. And even if they could, they don't have any back stock: they would have to find someone else to make the mould and start all over again with money they don't actually have while the lawsuit settles, which could also take years.
I don't believe for a second that the boards are any real bottleneck. If OPT suddenly found themselves with all 3000 remaining cases, I have little doubt that they could call up the factory in Texas, say "we need boards yesterday!", and they would find 500 complete boards on their doorstep in under 2 weeks, with 500 more trailing behind each week thereafter.
No, I am quite certain that if the plastics company were on top of their game, delivering the cases as they should be, the board populating factory in Texas wouldn't be far behind.
Which kind of turned out to be a blessing: if things had gone faster, we'd have had most of the 4000 Pandoras out there by now with a large proportion of them having bad nubs. Instead, the problem is discovered within the first 600 and the nub factory works to fix it.