Here's a picture of the mould been cut into a solid block of aluminium by the CNC Miller...

...And here we have the finished product. Note the two halves which go together.

Here's  the outer Saber just as it comes out of the mould. Note the sprue (or 'tree' as it's more commonly known) with 3-point injection just as the originals were done. This was actually the first-shot taken from the mould, as you can see, it is a deeper red than the final Vader Sabers.