Wayne (Elmo), correct me if I am wrong, but I recall you used PTFE which is a far easier material to mold than PC.
I used PC and it was very difficult. The molder did a very good job. There were three problems. One, my mold was not perfectly shaped and this, compounded with the thick PC I used, made optical distortion I could not seen to be able to sand out. Lesson learned, make a real good mold and use thin plastic.
Second, the thick plastic had a memory. It did not fit real tight against the mold around the edges. It was very slightly larger than the mold. his is a problem with PC.
Third, a special dry storage area is needed in a PC molder's operation so the stuff can be stored where it does not pick up atmospheric moisture. In Oregon that requires more than a dry room cause we are so wet here. It takes a dry and dehumidified room or storage locker. The moisture makes tiny bubbles in the plastic when the PC is heated.
If I was doing it over, I would use PTFE, for sure, and as thin as possible. It is easier to work with and it has less moisture related problems than PC. It should give excellent results if your mold is good. Or, I would have it done using drop or blow forming.