What i dont understand is how the 80's figures all had original sculpts and weapons but in the new millenium (where technology has advanced aswell as sculpting and manufactureing) they use the same molds over and over again.
It simply costs more money to make all-new molds than it does to re-use older molds multiple times.
This isn't a new revelation, Hasbro has been operating this way for 45 years now. The reason that you saw "less" of it during the RAH run back in the 80's is that the toy line was 10 times more popular than it is now.
GIJOE simply does not sell in the numbers that it did in the 80's--there's far less interest in it and the audience for it is a fraction of what it once was. Advances in sculpting technology and manufacturing processes mean nothing if there's less people buying the stuff.
Combine less people buying, with more costs associated with production and Hasbro is going to seek every possible avenue they can to maximize their profits--of which the expectations are ALSO higher now than they were in the 80's.