Injection moulding is still somewhat out of reach for small guys like us, although there are prototyping services offering it now. The problem is the tool cost

Injection moulding is still somewhat out of reach for small guys like us, although there are prototyping services offering it now. The problem is the tool cost vs. small production runs. Plus, designing good tools can get really tricky. Here is what I would do on the garage scale: * A CNC router like shapeoko or x-carve (you can buy or diy) * This allows you to build large, but rather flat moulds * Pouring epoxy resin mixed with e.g. cotton flakes or other additives gives you nice solid objects * Laminating glass or carbon fiber can net you large surfaces * Vacuum forming also nets you large surfaces and can be done with a diy machine Old, used machines are also always a good idea.