So I did some research on metal and resin casting. I concluded that the easiest would be to create my mold with Room Time Vulcanization (RTV) Silicone and cast liquid resin plastic.
Based on what I could find locally, I tried Smooth-On OOMOO and it was surprisingly easy. The starter kit is a really good deal. A pint of resin is sold 30$ on itself, and in the 50$ starter kit, you get a pint of resin + a pint of OOMOO, a spray bottle of sealer and a spray bottle of release agent.
Given the scale of what I wanted to cast, I was able to get a lot of mileage out of a pint of resin. I did not plan my molds and at each pour there was some loss, but here is what I was able to produce:
- 18 Daleks
- 12 Dungeon doors
- 32 25 mm square bases
- 2 small treasure chests
- a dozen small barrels
- 5 large barrels
- 36 balloon tires
I plan on doing some more doors like airlocks, but I'll need to get a new kit as after 10 months+, the OOMOO left in in the jars was almost too thick to pour and the molds I made had too many bubbles. I had to throw it away.