Sometimes the air pockets in the tail are caused by injecting too fast fast initially. Start out very slow then increase the speed and hold the pressure.
Unless you use PolyCarbonite or Ultem you won't get a mold that will hold up to the heat. I would use 3D printing for a prototype only. The best way IMO is to have a mild made with a 5 axis or a machined EDM electrode.
What are the hard and fast rules for keeping your baits in the correct shape? I try to put them on a cold plate but after a couple of days they go in my tackle box and kind of reshape themselves.