How about having a casting done and then milling an edge on it? I have a friend who is a machinist and has the castings done in china and then does the final machining in the US.
I can cast most of these, except for the stainless. I think that the initial mold is the most expensive part. I guess I'm going to have to look into a lot more options.
Hi,
Just to add to the confusion:
You should be able to have the part made by investment casting with very little tuning or machining required. And no stress in the blade to cause warping. I assume you use type 316. I fooled around with a similar project for a client; applying dye to large clear areas of ortho film keeping the same colour density. I came up with a viable solution but up came budget concerns so the project was cancelled.
Look in your phone book under "Metallizing". You could make your blades out of any easily machined steel and have them 'spray welded' with SS or titanium, then machined. These shops are normally near airports. Metallizing is also used to save really large castings and make large rollers for printing presses (copper on steel).