Let's see if I can answer a few questions.
Yes, the goal is to have all distributors sorted in advance so that they can get the product to retailers by the 28th of June, or as close as possible to that. Naturally, any number of things can go to shit between here and there, but we're looking good unless something pops up. Overseas and outside the US distributors get their product sent out first, then the US - that being said, each distributor outside the US picks its own manner in which to ship product and we are not responsible for any delays on their part (awaiting other orders from manufacturers so that it can all go on one boat for a cheaper price, etc, etc). Then of course if customs decides to get cute or weather decides to wreck a port or some other stuff. Outside of stuff like that, we're looking good.
Not everything is being resculpted - not even close. We will be updating/redoing crew boxes as time goes on, some sooner than others, particularly if there is a large change to their box layout as at the end of the day, time to cut/repackage/touch everything and the chance for screwup kinda outweighs just getting a new mold done. Some boxes will be getting a whole makeover. Others will have bits and pieces of it. People keep tossing about the idea that these molds are wearing out and thus the reason for XYZ - lemme tell you - we would have to sell a LOOOOOOT more before these things blow out.
We will be updating our Upcoming Releases, Retailer section and a few other things here over the next week to get additional information out, advertising images, etc.
Rules and cards will be released online for free. You can download them and print for your own purposes. They are not and will not be allowed to be tied into custom programs/apps - online or offline - nor for other folks to exploit direct sales from (printing cards out and selling them). They'll be some language letting you know what you can and can't do - we're pretty easy with it, but as with anything, some folks will happily ignore for their own wants/sake.
Drivethrurpg and Wargamesvault will have the cards available as a print on demand service and you'll have the option of picking up one card, whole factions, by keyword - etc. We'll try to make it as simple as possible. When the translations are available as well (hopefully at launch or shortly thereafter), these will also be placed online for POD. They are actively seeking a printer/partner in Europe and beyond, so if you have suggestions for them (contact them, not me) feel free, otherwise yes, all orders from there will be printed and shipped from the US.
Special orders, either directly from us, or from your retailer through distribution is available both inside the US and outside. That being said, it is only for boxes that have been combined or changed up in a manner that say only a single new miniature has been placed within a box (we'll use Alphonse for instance) and the only way you could get it would be to purchase the box all over again. We're not interested in jacking over our customers like that - but we're also not going to go in and allow this for each and every model in the line as that's frankly entirely too much work and ultimately self-defeating. Also why there is a time limit on this. If you're going to want a Wanyudo for your Reva, you'll need to purchase the box - we'll not be breaking that one up.
Small rulebook - we keep getting asked about it, so very likely we'll take a serious look at it after the launch. Wouldn't be overly difficult to manage.