Has anyone tried this? If so, how did it turn out?
I think if I can make a good mould that makes the tips close to perfect symmetry and consistent weights, Then that would be a success, however they would then need to be attached to the foam. Loctite 454 adhesive gel is the choice solution to get part A to stick to point B.
I might get one of the guys at work to make up an aluminium block with casting (mould) holes in it. Once I get a batch of 5 out, I'll run them through the BBLS into a hard surface (metal or timber) and see how long it takes to make them break.
Any ideas are more than welcome. If it turns out well, I'll get a system going to mass-produce them for sales.