"If sanding's your main worry, maybe look into smoother-casting resins or silicone molds that leave cleaner surfaces?"
Totally agree with this. I've done a few custom handles myself, and silicone molds paired with a high-quality resin saved me a ton of sanding time. Injection molding is fantastic if you're producing multiples, but for one-offs or small batches, casting just feels more practical and less stressful. Plus, tweaking a silicone mold is way easier if you need adjustments later on...
I've found silicone molds pretty handy too, especially when you're still experimenting with shapes or textures. But honestly, injection molding can give you a level of precision and consistency that's tough to match with casting—especially if your design has intricate details or tight tolerances. It does come down to scale though; for just a handful of pieces, the upfront cost and complexity of injection molding might not be worth it...
"It does come down to scale though; for just a handful of pieces, the upfront cost and complexity of injection molding might not be worth it..."
Yeah, that's exactly what I've found too. A few years back, I was working on some custom knobs for kitchen cabinets—wanted something really unique and detailed. Started with silicone molds, and honestly, they were great for playing around with designs and getting quick prototypes. But when I finally settled on a design with lots of small details, I looked into injection molding...and the quotes I got back were eye-watering for just a dozen or so pieces.
Ended up sticking with casting and accepting a bit less precision because the cost difference just didn't justify itself for such a small batch. Have you tried resin casting with pressure pots? That actually helped me get closer to the detail level I wanted without breaking the bank. Curious if anyone's had similar experiences or found other workarounds.
Have you tried resin casting with pressure pots?
I've had similar experiences—looked into injection molding for some custom trim pieces a while back and quickly realized it wasn't practical at small scales. Resin casting with pressure pots worked surprisingly well, though. Bit of a learning curve, but definitely worth it for the detail.
I see your point about resin casting being more practical for smaller runs, but I wouldn't totally dismiss injection molding—even at a small scale. I've collaborated on a project where we used aluminum molds instead of steel ones, and the upfront costs weren't as steep as you'd think. Yeah, it's not as detailed as resin casting, but if you're aiming for consistency and durability in larger batches, it can still be a pretty viable option. Just something to keep in mind...
