The issue with that is it only gives you a mold of one side, I still have to account for all the mounting posts on the backside and the posts to mount both the air vents, that is where the High dollar cost comes in.
To do a injection mold of for just the front is only about $3,000 to $4,000
Is the higher part of the setup cost on that making the mold or doing the initial impression? I'm wondering if this might not be able to be vacuum-formed, but it's a complex shape in a lot of ways and the original materials may not like that process.