Get some proper moulding Addition-Cured RTV silicone, like Dow Corning
Silastic S-2 or similar.  They are initially expensive, I think I paid
about $80 for 1.1kg, but they would make a mould that is reusable
hundreds, if not thousands, of times, and readily flexible so your
parts just pop right out in 2 seconds flat.  Available in different
shore hardnesses, choose one that's flexy enough to pop your part out,
and has a high tear strength.  You don't even need a release agent,
but a quick spray of a proper release agent can greatly extend the
life.=20

	Do a youtube search and you'll find vids on how to make moulds, and
see them in action.  Well worth the initial cost if you are doing
thousands, only need to machine up the one initial set to base the
mould off, no more time required machining for each mould run.  And
1.1kg should make you a whole heap of moulds of your required size.=20

	some info:
http://www.erapol.com.au/english/Products/Silicone/Addition-Cured.html
[1]
 Lee

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Links:
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[1]
http://www.erapol.com.au/english/Products/Silicone/Addition-Cured.html
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