Another tip, to save some plastic on prototypes: if you have a paper printer you can make a technical drawing in your CAD program, set scale to 1:1, print it out and compare (make sure to measure to check that the printed size is actually 1:1). If need be use scissors to cut out the profile.

This won’t take plastic shrinking into account, but in my experience it can remove the first few iterations at least. And it is way faster, and paper is less bad for the environment.

I would go back to your CAD model and tweak it for better printability. If it was a model you downloaded and without a source CAD model I would just remodel it myself to be more printable.

What about the UV cured polymer that dentists use? Surely that is relatively safe, though probably way too high viscosity. (Note: While I know a fair bit about FDM, I’m not at all read up on SLA, so I may be completely wrong here.)