The parts I want to cast are very simple and don't really require a two-part mold (the bottom side of my part is completely flat). However, I thought it might be interesting to use the two-part mold as a way of getting two separate parts out of the one mold; the parts would be separated by a thin plate that would be inserted into the mold before pouring, diverting the flow into two halves, leaving only a small portion at the top of the pour to trim in order to separate the two parts. Let's see if this works ...
We did two rough cuts, one with a 1/4 in endmill and the second with an 1/8 in. Probably about 3/4 of the way through the second cut, the 1/8 in bit broke (not sure of the exact cause). Chris suggested we move ahead with the final finish cut (changing the tool to an 1/8 in ball-end bit), but at a reduced feed rate ~20%.
Files: wax_mold.step