When it comes down to it there is nothing better than manual tools for your Lock pick Set, whether they be retail, homebrew, macgyver style. DIY'ers look here.
I found some scrap corian which is a material for making countertops. When heated to 325 degrees it becomes like rubber and then hardens back into its granite like texture. This process is called thermomolding. I will post pictures if it works out.
I never thought about making a handle mold like that, very clever! I like the ability to sand down the material so it's comfortable and smooth as well. Well done! I think I'll be doing this for my home-mades as well.