My rough process would be: create molds (from unknown material) Manually mix and inject some kind of resin/thermoplastic into mold Repeat as necessary

What can be used to create a mold? It needs to be rigid so the moulded parts are in the correct place, as in silicon would give too much variation.

This is in a repair context so it needs to be moulded onto an existing item where the moulding process is the only thing bonding it on. The original plastic parts were POM.

The application called for a two-part injection molded Delrin enclosure and a die-cut gasket. Specifications include electrical isolation, flexural strength, and most importantly the ability to remain waterproof at depths of ten feet or more. During the prototype stages, the customer added an additional specification. Accordingly, this called for the enclosure to be field serviceable without the use of special tools.

Through prototyping and field-testing, we were able to supply an enclosure that met the customer’s specifications. As a result, the enclosure is currently being injection molded in a two-part family mold using Dupont’s Delrin 100. Furthermore, this component is molded under strict guidelines to ensure part integrity and a waterproof enclosure. To aid in waterproofing, Jaco provides a die cut gasket that makes the seal between the lid and the enclosure.

A supplier of electronic enclosures to the blasting industry called on Jaco with a demanding application. That demanding application required the injection molding of Delrin plastic.

Jaco achieved this specification by adding external ribs to the enclosure to ensure strength and to retain a castle nut. This allowed the user to service the enclosure in the field without the need for special tools.

Obviously very new to this field so I'm just trying to gather some info on which avenues to explore so any resources are much appreciated.