One of my major products for AAs are my
pirate and
ninja restroom signs. I currently use a two-part polyurethane casting resin mixed with a dye paste to cast them, in a latex mold.
This works... all right. The photos are old, I've gotten better at making them since then, but some of the flaws still remain. The polyurethane tends to form an irregular surface, and is porous so I can't sand it down. When I CAN sand it down, the surface is still kind of grainy. Once I run out of resin, I'd like to try switching over to a new sort of plastic. Anyone have any ideas?