Have an optical scanner laying around?
Wax paper or something with a lot of lubricity. Pour plaster of Paris in a box with the part it it. make sure you have a way of opening the mold. Lay fiber glass around the mold and presto. Not good for mass production. Ok for one-offs
Make a fiberglass mold, make parts from fiberglass, or carbon fiber. That takes some work, but a mold would make a lot of proto parts.
It does take work. As far as making many proto parts, when I was in formula sae we got dinged on using a mold and fiberglassing our plenum. It takes too much work to produce many parts out of this method. It works, but it's not elegant. A better way would be more expensive, too much for in-home use.
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