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I was thinking the same thing about using PTFE. We machine it alot at my job. Kicking my self because I just threw away about 25 ft that my job threw out years ago thinking I would never use it. If molding delrin is the way to go for sure. I have designed several molded parts out of it. The volumes are pretty low to justify a mold but I have seen some temporary molds produce excellent parts for runs under a couple thousand. You can probably get a temporary mold for around $1000-2000.
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