|I really to wanted to get this project completed and checked off my list. There was absolutely no other way to do this properly besides injection molding.
To be honest, I regret trying to cut corners by experimenting with other approaches for years. I wasted way too much time and money postponing the inevitable.
Yes, tooling costs a decent amount, but the results are as close to OEM as I think a small business can do.
There has been a decent amount of interest in this project after sample pictures were posted, so I think tooling costs will get covered and then some.