The problem with your plan is that making the molds is exceedingly expensive.
When I was a manager at t plastics factory some 12-15 years ago the average mold would cost somewhere in the region of $50k(NZD) to make..... I doubt prices have come down much.
Mind you those were for blow molding and injection molding for materials like HDPE, LDPE, Styrene, PVC etc etc.
Ask for Jason Brown. He's a racing buddy of mine. He's actually one of the machinists, but if you ask for him or mention him in an email, he get's bonus points.
ABS would be too rigid for a bumper lip. I'd go with polyurethane no more than 1/8". Have you considered making your own from a used bumper or an aftermaket bumper? A jigsaw, heat gun, vice, and a ruler might be all you need if it's gonna be a oneOff
I have the original parts, as well as the bumpers to ensure fitment is correct. I wasn't thinking of making 1 or two but a fair amount. Theres a high demand for this part but its nla via VW worldwide.
Im fairly certain the OE parts are all abs plastic, but I've never looking into it until now. I know there's some flexible fiberglass but i'd prefer not to go that route.
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