I haven't had that problem with the plastalina. It softens up as you work with it for me.
You have to expect 3d printed parts (and often custom made pieces) will be damaged or destroyed when you remove them from molds. I've even seen it mentioned on some 3d printing sites. As long as you can get the part out, you'll have a master part once you cast it (provided you don't damage the mold when removing said part).
You could also use pieces from older molds as a frame work for your parts. Just make sure they're not too old, the more recent the better. I can also recommend Smooth-On Max 10T for the mold. It has a little more give than the Max 15T so removing parts is easier.