This might be from someone who is a Bachido member. I bumped into this online, read it and thought it was interesting. " Bachi Casting
What follows is a description of my attempts at jiuta bachi casting and customization using RTV silicone in a two-part mold with clear epoxy resin as the casting material."
I probably wouldn’t try casting, but I have thought about (just an idea for now) epoxy-gluing Delrin/acetal and/or other thin sheets then sanding to shape. Something like these very neat custom guitar picks (by Pick Punch), layering colors or adding graphics or writing. Probably not using polycarbonate or Lexan, since I like Delrin, and maybe Ultem for sections that need stiffness/low flex. Anyways, take a look at these neat guitar picks just for fun.
http://www.pickpunch.com/newobject.html
http://www.pickpunch.com/plastic-sheets.html (available plastic sheets, which can also be purchased elsewhere in larger sizes)