I got to speak with Romeo and Jaima personally at Lock 'n Load. Great and friendly people, by the way. I talked with Romeo about how our new Bane Thrall sculpts don't fit into the old BT trays. He said he had heard something along those lines once before, but wasn't able to get any info about it. So I told him how the new sculpts come in a box set of 10, along with a Unit Attachment of an officer and standard bearer. I said the old sculpts are still available in the online store, so the old trays were still viable and useful. He pulled out a box of the new sculpts and took a look at them.
He told me he would make a new tray for them right away, and to look for it as early as this friday, June 8, 2012.
I told him how I read about the issue on the forums, and he asked me to pass along the news here, since I would be able to get to the source faster than he would.
So, great news, new Bane Thrall sculpt trays for Battle Foam!