I've been watching this thread. Have you looked into SLA Quickcast?
They 3D print a plastic pattern, mold a slurry around it to form a mold and then melt the quickcast plastic plug out of it, to make way for the aluminum pour. It's way cheaper than printing a complete plastic manifold, since it's like hollow foam, doesn't take much plastic and is is much quicker to print.
https://www.protocam.com/additive-ma...iAAEgJDGPD_BwE
FWIW,
Eric
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