Wow, guys, I'm really amazed by the sheer amount of feedback I'm getting here. Thank you so much for all the positive comments, it is indeed very much appreciated and makes me keep going.
I also feel very honored seeing that my work was suggested to be archived, thank you very much.
Now for some questions:
1. I'm using modelers plastiline for the clay bed. It's some special stuff that doesn't prevent the silicone from curing. Other than that it's nothing special i think, but it does indeed come off quite easily.
2. Concerning the hollow-casting: I hope the advice from RedTwoX was helpful. Just look at the pics again and it should become clear how I do it. If not, I can elaborate that further.
3. I did cast the piece with the LED window already cut out. The mold was designed that way. If you look here, you can see it:
The window is not entirely cut out, but the resin is very thin in that area. As for the battery door... Well, as someone here said, i planned this project quite thoroughly, but not all that thorough after all. I guess I just didn't think about how to do the battery door up until the point i actually did it... :rolleyes
4. The pictured version of this prop doesn't have a backlighted display, that's why i didn't replicate that feature. However, the same prop was also used on Voyager, where it got redressed quite a bit, including a lit-up display:
I might indeed do that version in the future...
And lastly:
5. I pour a part of the resin into the silicone mold until the "floor" is covered, then I insert the inner silicone piece and then pour the rest of the resin through one of the larger openings until the mold is completely filled. That way I can avoid bubbles by displacing the resin inside the mold. I hope this was comprehensible.
Oh, one more thing. I forgot this in my original post:
The ODN Scanner in action.