As a kid I tried something relevant to this,
I pressed aluminum foil over parts from two directions
filled each press with epoxy, then assembled, sanded,
& painted the result. Kinda fun, if time consuming.
For this day & age I typed "stereolithography" into
Yahoo.com
and found a bunch of sites for that. The technology has been
around for some time so the price must be coming down.
The service started in the $1K/up range maybe 10 years ago.
John A.