Im trying to make Al alloy molds with small 0.01" and smaller features. The depth can also be equally small. I want to be able to have the mold be essentially mirror finished and smooth so I can cast clear plastic and that it remains optically transparent.
However I cant use conventional methods like use a buffing wheel etc that you can do on larger mold parts.
So whats the way to get good mirror finishes on these molds?
Also critical is that I want the mold to maintain geometry, e.g. 90degree straight edges should remain 90 degree after polishing, so say buffing techniques are sometimes not suitable because they round out edges.