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I ran a vac-forming machine for a few months at a short term job back in the nineties.
You'd make the mold's inverse out of casting acrylic, place it on the machine, throw a sheet of plastic in the clamp jig and press the cycle button.
The heating elements heated the plastic at a pre-determined rate then dropped it over the mold as the vacuum kicked in.
If you could find a shop that could vac form for you... Maybe you could make the molds out of the corian and use the food safe mold plastic to make the molds?
I don't know how well the corian would release the mold once it cooled or how much detail would be retained, just an idea.
~ Mark K
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I LOVE this project.... one of my all time favorites I've seen done on the Carvewright. THANK YOU
Lawrence
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