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

Actually, I was no longer asking the question as to how to do those types of shapes. The images are cavities that I did create (and they are fairly lightweight CAD, I might add). I now need to go beyond what was done with these, and was doing my due diligence in research when I stumbled upon this old post. I've been working with an individual that does training when companies bring FreeForm in-house, and his experience is that FreeForm has a fairly short learning curve for someone coming from either sculpting or CAD backgrounds. I guess we'll see if we go that route.