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If a thread get started on that, I will probably jump in too. I am just playing around with the one in the shop at school guessing feed rates and noting how well they work. I found a few documents that have example feed rates that have been the best of my tests so far. I also need to play with the settings on the plasma cutter a little bit too.

Milling these would definitely be the way to go without a waterjet, but milling is slower and more expensive. If I drag this project on long enough to last until I get back to work this summer I might use these as one of my pieces for learning HSMworks. Low volume part that would be cheap enough for me to order my own stock for.