Hey mac,

I see a fluid choice on all of those. A unique approach for each. So questions need answered for each throughout the process.

So for something like the red screaming face, model it with all hard edges, and a 3d toolpath with a ball mill can "smooth it"...
Limitations are ALL smoothing is same rad. Also, looks like vacuum moulds. Would work for that, but, not for 2 part moulds. Some of the others are different methods, but, maintaining something precise to a sample kindof falls out the window...

Why the need to remain cad?

"You're going geomagic"? Start the tutes NOW!!!! Lol

Anything trying to convert mesh to nurbs is either heavy, sacrifice, or problematic in the mould side... (unless you go geomagic and do the learning curve....

2 cents