This is fun project to follow along with and like the idea of sculpting over laser cut parts. You'll still get shrinkage in the molds, though, so maybe plan for that. The Dwarven Forge stuff for example is built on a the idea of 1" squares but the squares are somewhat smaller in reality, at least for the the earlier sets (Realm of the Ancients seems more true).
I like the idea of laser cutting in general, and use laser-cut bases almost exclusively, but with obvious join artifacts and lack of details I think at least at present applications like you're doing here are better suited to the medium than trying to sell laser cut structures or what have you.