Powder Metallurgy is widely used in the auto industry for making everything from fuel filters (this is where the porosity advantage kicks in) to planetary gears for transmissions. In some case the compacts are made of just one alloy, in others alower melting point alloy powder (like copper) is mixed in so the part can be "bonded" at a lower than sintering temp. This can produce incredibly stong, tough, and hard units like the gears. Tungsten alloy parts for aerospace/ military are made exclusively by this method. This would definitely be the way to go if RB could convince the bank that they'd sell 20.000 or more units per mold. 10 to 15 K is usually considered the break-even point in this type of manufacture.
Titanium Frame? I'd shell out 2 grand for one without batting an eye. Seems very doable with a nice margin if they farmed it out. For a gun frame I think simple investment casting would do the trick, considering the lower production numbers.
CNC would work too, but the frame would not be as strong. I'm not sure drop forging would be cost-effective
This new casting process:
http://www.azom.com/details.asp?ArticleID=286might also work, but would definitely push the cost up to PM comparabiltiy. I'd go with lost wax centrifuge casting to keep the cost down.
So, when does RB start taking orders? `:~>