Yes! Today I bought 20 identical poorly-injection-molded T-fittings for aquarium air hose, and I was thinking about your comments. It occurred to me that the existence of injection molding strongly favors designs that have several instances of the same part, like four identical wheels or 15 identical spring clips.
In some cases I think there are materials that are a lot easier to shape to make a mold pattern than whatever you're going to make your final part out of. Wood is the traditional choice, except that wax is the even more traditional choice, and clay, styrofoam, foamed waterglass, and pumice also come to mind. I guess in theory polycaprolactone might work, too, and as you say, poly(lactic acid) is a popular modern choice, sometimes painted or sanded to smooth out the print lines. And I've been wondering if it's feasible to strengthen aluminum foil by spray-painting or cathodic mineral deposition in order to make such one-off items, because aluminum foil is very easy to form, usually too easy. Lots of stuff to try!
In some cases I think there are materials that are a lot easier to shape to make a mold pattern than whatever you're going to make your final part out of. Wood is the traditional choice, except that wax is the even more traditional choice, and clay, styrofoam, foamed waterglass, and pumice also come to mind. I guess in theory polycaprolactone might work, too, and as you say, poly(lactic acid) is a popular modern choice, sometimes painted or sanded to smooth out the print lines. And I've been wondering if it's feasible to strengthen aluminum foil by spray-painting or cathodic mineral deposition in order to make such one-off items, because aluminum foil is very easy to form, usually too easy. Lots of stuff to try!