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[jcfx]

Casting is duplicating ...

[jcfx]

If you want to make a rigid negative ( reverse ) of the part that you want to use on the tracer mill, you'll have to make sure
that original part...

[jcfx]

I did something a few years back where I had to glue delrin to a aluminum plunger, the glue manuf had a video on how to plasma treat parts
the blue...

[jcfx]

Why not try a delrin bushing instead ? The friction coefficient of delrin vs teflon is very close.
You're still going to have issues with gluing,...

[jcfx]

I'm not sure what you're trying to make, a jig or a pattern ( sounds like a pattern ) ? Tooling foam or insulation sheet ?

For polyurethane...