Having looked into this a bit, and after contacting every company I could find before finally settling on Westone for my mods, I have a possible answer.
The mods created from ear molds are made of either hard or soft material. Hearing professionals typically take a casting of an ear, send it off to a company (i.e. Westone) who create the hearing aide, music-plug, swimplug, etc. directly from that cast. The device is then sent back to the hearing professional who then shows the patient how the earpiece should be worn. About 10% of the time (a figure I'm quoting from my audiologist) the earpiece is not an exact fit, and a tool (her office uses a specially designed "bench-grinder" and a Dremel) is used to smooth or remove areas in order to produce a perfect fit.
In the case of soft mods, nothing can be done to the earpiece once it has been cast. If it doesn't fit, you have to retake ear molds and send them off again. I asked Westone about this before deciding to buy my mods from them they told me I could simply send in the faulty mod with a second cast and they would make another mod for me. If the earpiece is not identical to the ear canal there will be problems:
1. Too big = discomfort (the level of discomfort varies, but the earpiece can still be used)
2. Too small = no seal (without a seal, the earpieces are useless)
Now for my rudimentary knowledge of the ear canal. The canals do enlarge a bit when one opens one's mouth. The wider you open, the greater the increase in the size of the canal. So, by taking an open-mouth mold, you are more likely to prevent the earpiece from being too small and therefore unable to create a seal. However, the ear canal does not simply increase in volume as you open your mouth. The SHAPE of the canal changes as well.
SO, if one takes an open-mouth cast, they will most likely have an earpiece that creates a good seal, but not necessarily have a perfectly comfortable fit.
If my audiologist's figures are correct, by requiring customers to take open-mouth casts, UE will avoid seal problems on a large proportion of their earpieces, but at a potential cost in comfort.