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I would look at products from Smooth On, I think the company is. This is a company that makes plastics that are 2 part like epoxy. I just gave some left over urethane that I had from probably 15 years ago to a buddy.
Every thing is done at room temperature. A part could be made from aluminum and used to make the mold. Plaster of paris is good for the mold, which could be made in several parts.
Spray the aluminum real good with silicon, and pour some mixed plaster around it. Before the plaster of paris dries completely make some dimples, for alignment. After it dries, respray and pour another part of the mold. A simple 3 part mold would probably do. With a file, openings for pouring the plastic and air release could be easily cut in the mold.
Plaster of paris isn't the most durable stuff, but is easily changed in the prototype stage. Several molds may get you the 50 castings. Except for the original part, $100 is invested. But then like 3D printing, there is the time. From memory it is several hours before a part can be removed and handled.
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drew1
wife has 924 turbo
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