On another group a fellow mentioned cutting gears out of Nylatron GS. A quick google/wiki shows that it is a nylon plastic filled with moly. It looks similar to aluminum in appearance.
The wiki article also stated that it can be cast.
It looks like a material that should be easy to machine and you can save the scraps for your die caster :)
Product ID is Nylatron GS, there is a seller on ebay plus online metals carries it.
JohnW
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