Update addition to post #44

Completely forgot.
those 4 individuals that are needed?
1 coordinating?
1 with 3d printer skills?
and 2 people to do mold and cast work from the master?

You don't need the guy with 3d printer skills...
nor do you need expensive equipment...
nor the time and money taken...
Nor a master in antler for resin casts...
None of that to produce a master.

Hehe...forgot completely!
When I 1st started doing resin work...I didn't start (way-back-when) carving antler masters for the molds.
I used artist (sculptors) plasticine ...
Pretty good stuff...not cheap to buy (in bulk even) ...spent a few hundred on about 20 lbs of it...varying density.
But you can use it over and over and over and over again. Making it a very smart investment.
I still use mine decades later for a couple projects now and then...stuffs great.
Need a good eye and a good hand...a good dimensional artist or sculptor can make the master in the plast. and then do your mold and voila! copy ready.
I stopped very early in doing plast. masters tho ....
For my tastes I found it too delicate and too easy to mar the plasticine master...even in the handling of it to make the molds...and so opted for the detail certainty of antler and it's definitive ability to hold it's shape as well as other qualities.

Artist Plasticine is a viable option in a pinch though.
And there are other methods similar using foams that can be sculpted and cut...need someone capable though.

So technically.... fancy machines and high expenses are not needed at all ...
with multiple methods of master creation...mold creation and finally resin cast creation...
thereby eliminating a great deal of overhead spent on machines, specific skill-sets, materials, facilities and fabrication.

Update:
Current casting techniques include:

1- Textures (wood grain, stone, marble, metals, etc..) (cool)

2- The ability to add more diverse "foreign content" to resin mixes...
Bronze powder...Steel Powder...Brass...Aluminum...list goes on.
Enabling the addition of increased strengths over the original material with the aid of the resins yet maintaining the ability to fool the eye, the hand and metal detectors as well. Can't tell the difference between metals and resin with metals at all anymore.

3- Silicone mold material to pick up intricate detail..
CAREFUL now...it'll pick up FINGERPRINTS even! wow. (freaky)

4- Malleable epoxy putty (like bloody "Play-Doh" ) that can be shaped around a master and dries to create the mold (pretty freaky)

5- Fire resistant resins. (No need for added antler dust to the resin mix thereby reducing time and material costs) (very freaky)

6- Indestructible Resins.
No....REALLY!
Truly indestructible resins....
no need to worry about cases, bodies or parts breaking ever-ever again...No need to fear for your device when it slips from your hand (shy of exposed lcd screens)...or feel you stomach drop when you sit down and it's in your back pocket...or stepped on...or run over... (No need for added antler dust to the resin mix thereby reducing time and material costs) (uber-freaky)

And more way-cool stuff and techniques....

the materials and end product have advanced ...but the methods of application...of actually physically doing the casting haven't really changed much at all.
Very minute learning curve involved for me or any beginner for that matter.
So you don't have to pull out your PH.D's nor your slide-rule's guys.

Hell ...if ever was a method was created that was perfect for what is needed for this community. THIS is it.

Personally have little faith in speed or cost or end result using 3d printing and assembly manufacture.
By the time such end product is ready for shipping to the end-user the customer has moved on in interest and motivation to the latest technology...hence the creators are always fighting the wave of progress.

Personally I believe in the method, speed, end result and the cost in hand making masters and casting.
Personally ...I loved making copies by mold and resin casting ...but that's my opinion...

A few have voiced it is a wonderful idea ...but don't take their or my biased word for it.

Here:

A DIRECT application with a phone body (albeit an old phone ) pulled out of a fresh mold.



Our Community prides itself on being cutting-bleeding edge...
Why then think in archaic creation, production terms with machines and factories...what do you think the competition and other industry is doing?..

http://www.smooth-on.com/Prototyping...238/index.html

quote: " It All Starts With An Idea . . .
It all starts with an idea for an invention or product that you think has commercial potential. On your way to developing your idea, you will need a three dimensional physical representation before you go to production and that's where Smooth-On rubber, plastic and foam materials come in.

Smooth-On materials have been the tools used to make prototype models for over 60 years and are still instrumental today in bringing the world's most amazing products to market.

Who Uses Smooth-On Materials To Make Prototype Models?
Our prototyping client list includes Apple Computer, Dell Computer, NASA, SONY, General Motors, Ford Motor Company, The US Army, Boeing, Advanced Medical Devices, Martin Guitar, Disney, Bose, Moen and thousands of other industry leaders around the world." end-quote.

And that's just prototyping ...
Why not the entirety of the process of making copies as well?
I used to do it...
This isn't new people.
And ...
if the competition is doing this...
if EVERYONE else and their brother is doing this affordable method...
why aren't we?

Final Update:
Abandonment of mass reproduction goals.

Experimentation, creation of parts, protos and enhancements for devices ....continuing... for personal interest and use.