Injection moulding woes

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I never used it to cast anything, but did use this to repair an old car (1955 ford) steering wheel once. Pretty much matched the texture and appearance of the original plastic. Lot of good information on the site too. https://www.alumilite.com/
 
Disregarding the legal problems for now (though I think you are batting on a sticky wicket there):
If you want 10 then 3d printing is the way to go.
If you want 100 then 3d printed resin mould then make yourself.
If you want 1000 then Al mould.
If you want 10,000+ then steel mould.
 
POLYVINYL ALCOHOL (PVA) is a mold release agent for casting polyester resins.
A Google search for "pva mold release instructions" will give you a lot of good info on casting & mold making.

https://fiberglasssupplydepot.com/PVA-Frequently-Asked-Question.html
For additional information on the benefits of using PVA (particularly on new molds), please read **broken link removed** by Bob Lacovara (Fabrication News, Feb 1991).

The Prop Builder's Molding and Casting Handbook Is about making theatrical props. One section is about making flexible RTV silicone molds that might be perfect for your parts. Also info on latex, plaster and many other methods.
 
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