Creating the mold cutout

Ever needed a piece of plastic a certain size and thickness?  I feel like i always do.  Well the good thing about having liquid plastic around is you can just make yourself a piece of plastic.  So that's just what we did.  Using our trusty mold box we made for the rubber mold out of sculpey we just filed it up with with liquid plastic and 10 minutes later we had that white piece of plastic you see below.

To create the rounded edge shape of the product.  I first created a rounded rectangular box in adobe and printed it out until i had a rectangular box that was perfect size and rounding radius.
Then exported the gif to hpgl file format so i could use the CNC isolation milling machine to cut out the piece of plastic which we could make a mold out of.

After fighting with the machine's software to get it to scale it properly we were routing it out.