I contacted smooth-on and alumilite regarding caster recommendations. Smooth-on refered me to their list of casters on their website which I've already been through. Alumlite actually has a caster on staff and will take a look at the project themselves. At this point, I've got 4 quote requests out to casting shops. I'd expect to have something back on these next week.

Anyone heard back from _hardcore_ or Brian?

It would be good if we could get some machine/prototyping shops involved per gbeer's efforts to find out if injection molding or variants are feasible and cost effective.

Firefox did you want to chase the list that you had? I can try asking around otherwise.