[Seth Mallory]

Originally Posted by DonRotolo

Don't have a machining recommendation, but consider this:

It is possible for you to make a mold of a nylon rack and then cast a duplicate in Aluminum. The hardest part is melting the aluminum.

Make a flexible silicone mold, cast a rack from wax, add the sprues and vent holes in wax, make a plaster mold, melt out the wax, pour in molten aluminum. Pewter is a reasonable alternative to Aluminum if you can't generate a lot of heat (melts as around 750F), but can accept a somewhat heavier and weaker material.

You can also make a 2-piece plaster mold if you prefer, but a bit more difficult to get good results.

There are a lot of artists and some school art departments that cast metal. If you have a mold they could help you out. We used our art department once.