Casting/ Resin info needed

[Daniel]

I have been looking at trying to do a buy on drill bits sets custom for penturning. This set would include all the sizes of bits any kits requires to make including all fractional, metric and letter size bits. One problem is that there will be no index to store these bits in. I have thought of trying to find a place locally that could make them stamped from metal like most drill indexes are, But I don't like those int he first place and storing metal in metal goes against what I was taught for how to care for cutting tools. I also thought of making a really nice looking wood rack for them which is really my favorite idea but it would also add some cost to the set. I will probably offer something like this as an option but for those that do not want to spend more or want to make there own. i would still like to have something to hold the bits in the mean time or for shipping. for that I was thinking maybe I could cast something out of plastic.
I know a mold would have to be made but do not know what is a good material to use. I have a 1 foot square of phenolic plastic sheet (not sure of the spelling) it is the stuff that super glue is not supposed to stick to.
I've thought of ways to make it from metal with rods to make the drill bit holes. Then I thought I should just ask here and see if anyone else has already invented this wheel.
I am thinking of a small, thin wall hard plastic box that will hold 35 bits ranging in size from 1/4 inch up to 37/64.
I do not mind having to spend money to make the form but the final box needs to be both relatively quick and cheap to make. as in I don't want to be wasting a lot of resin with overly thick walls.
I suspect the thinner the walls get the more problems I will run into in getting a solid cast as well as room to separate it from the mold. in addition the whole thing needs to be able to fit into a small video priority mailer with the bits in it.

For now I am looking for suggestions on both what material to make a mold from
Should it be a two piece mold or a single fill from the bottom mold.
and what resins do you know of that are low cost and will work?

 

[workinforwood]

Personally, I don't care about what the bits go into. I'm more interested in the cost of a bit set, and prefer all brad point bits, especially the large bits. If you provided a holder, well, I'm lazy and the bits would all end up in a pile beside the drill press and covered in drill shavings, which is fine by me.

 

[wood-of-1kind]

Daniel,
I had thoughts of putting together a "penmakers" drill set based on the discussion(interest) generated about a year ago. My thought at that time was to put the set together is a sewn canvas sleeve similar to how some chisels are wrapped and stored. The drill bits were to be purchased in England but I just could not bring the set in at a reasonable transfer cost. Good luck with this project as you move forward.

 

[Daniel]

Peter, Thanks for the idea, I actually really like it. And I can sew. My biggest problem...I just got rid of my sewing machine. I had not use it for years so you know how that goes. get rid of it and than is the surrest sign that some need for it will come along.
In all the little bundle of bits turns out to not be as little as i was thinking it would be, nearly 5 lbs of bits in all.
I am not sure just what style of bit I wil offer at first. to start I thik it will be regular TiN bits just to try and get the first order under way. Price is no question. even with shipping taking a pretty good bite these bits are a great savings.

 

[bitshird]

Daniel, your best bet for a plastic holder would try someone that does Injection molding, just be sitting down when you get the mold charge