I used to build competitive model airplanes a couple years ago. We mostly had positives milled from MDF (cheap), prepped those and then took the negative from them. Once worked with a mould directly milled out of some sort of PU (was probably Ureol or sth, not sure), was pretty nice to work with as well. Obviously, with MDF and lots of prepping, our moulds weren't 100% exact, but we're talking way sub-mm here. Could see if I can find some pictures (or old moulds) if interested.
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