Ok, so for the last few moths I’ve been playing with carius addivtive printing technologies, aka 3D printing. Unfortunately making molds for later mass production have prooved really really rediculously goo… difficult. Also my rapman couldn’t provide the resolution I wanted. The shapeways method would prove too costly in the long run (although I still plan to have that available as an option for people). So I turned to a methos that had been bugging me for at least two months. Ever since I read this http://lcamtuf.coredump.cx/guerrilla_cnc1.shtml
Basically CNC milling is the grandaddy approach to making things. It is the method that makes the molds for injection molding parts, so no new techniques to develop. 
So I brought one of the CNC 3040 machines that are all over ebay. A few days of sorting it out and getting comfortable enough with things to turn it on. I also used the MeshCam software to write the Gcode and EMC2 on Linux to control it. I further went and brought some milling wax, as well as a 1mm end mill bit, since the CNC3040 only came with a 1/8th inch end mill.
I’ve milled a test mold and can report that apart from a few gas bubbles in my test piece, the results are far better than any other attempt.
Being able to reliably make molds has also lead to another advantage. I can make more than two part molds, which means I can include holes on the sides of the parts. This doesn’t sound like much but it will make a world of difference, since I can make holes for tendons, and for the hinges. So all in all things are coming along pretty well, for once!
Hi Chris- thanks for mentioning MeshCAM (I’m the developer). I have a lot of equipment to make prototypes and my favorite for making small, detailed parts is still my mill and casting equipment. I did a short writeup of one of my projects at http://www.machinistblog.com/casting-small-parts/ to show some of the highlights.
If you can get a pressure pot then I think you’ll be surprised at how easily the bubbles can be eliminated.
-Robert
Hi Robert, thanks for the comment. It was getting quite lonely in here! I’ll see if I can get a pressure pot, although I’m limted by budget, space and what ever my girlfriend can tolerate in our apartment!
In my most recent tests though bubbles are being quite well behaved, so hopefully they won’t be a major issue.
Ohhhh do i envy you. I’ve been trying to find a way to create small molds of my STL files as i tired of creating silicone molds using my pressure pot (there is a ” poor mans” way to make one btw..its worked well for me for over 5 years). One day the cnc shall be mine…..
I was so excited forgot to inquire…
The CNC 3040…would it be capable of cutting a small mold for a 2 inch keychain figure of a “cartoon character”? I’ve held off due to my being unsure about that…
Hi Glenn. That keychain sounds like it would fit within the cnc3040 work space. Also what was the ‘poor mans’ method? Wasn’t quite sure what you were saying there.
Chris
Sorry for the lack of a detailed explanation as i was red eyed from research and tired 
Often individuals use paint pots that are modified to become pressure chambers. That can be relatively expensive. Truthfully my most reliable and stable unit was made from a Betty Crocker Pressure Cooker .
No..i’m serious.
5 years running with no problems and countless projects that would not have come out successfully without the unit.
Chris i’m strongly leaning towards purchasing the CNC unit you have but i’d like to know if it can do exactly what i have planned for it. Would you be interested in taking on a very small test commission?
Hey Glenn, sure I’d consider it. I’m ‘away from the office’ right now, but if you send me an stl, I’ll take a look and see if it’s doable.
If your interested in a bit more information regarding modifying the pressure cooker let me know. Also how do i contact you? E-mail links or Instant messenger links arent anywhere to be seen that i can tell….
I’ve sent you a private message via Shapeways forum (i’m a member there as well).
Any chance you want to share your emc2 hal file?
I’m having problems getting mine setup – had it working, then hdd crashed, and can’t seem to work it out a second time. Sort of have it going at the moment, but everything is inversed.
The emc2 manuals are less than helpful..