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Post date: Jul 14, 2014 12:29:23 PM
What about molding them slightly oversize and then having a second fixture that holds them for sizing and polishing? I think I could easily do a larger run and polish them with a buffing wheel. If I pick the materials right, I might be able to vacuum cast them (it's simple with a pump and a bell jar) to eliminate voids.
Another alternative would be to go ahead and machine them. Or laser cut them? If I can cleanly cut 0.125" diameter by 0.060 blanks, that would do the trick. Time to look for some acrylic sheet in the right thickness.
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