I would like to produce a replacement panel for the interior of my Xterra. I know how to create the (non-plastic) prototype... but does anyone know how I might produce such a thing in a limited run of say, 25-50? Vacuum forming, injection molding, or machined-plastic?

 

If you have a mold ready to go, you can contact an injection molding company to produce them for you. I am not sure if 50 is going to cut it though. You usually want something in the 500 area to make it worth your/their while.

 

That's the problem I'm running into... injection molding appears to be the most expensive route (by far) due to the cost of tooling, creating a steel (or mahogany) mold. I was thinking of a homebrew solution like this... www.alumilite.com. Think casting resin could work?