What about forging? Rough out the shape from AlZnMgCu1,5 (EN AW-7075) alloy, heat to 450°C, and slam it between a pair of dies. Compared to cast or machined pa

What about forging? Rough out the shape from AlZnMgCu1,5 (EN AW-7075) alloy, heat to 450°C, and slam it between a pair of dies. Compared to cast or machined parts, you get a 20% higher strength-to-weight ratio from the forging. The cycle time is decent I think, perhaps 3 per second with a 0.06 second contact time in the dies.