[Hack]

First of all, what is the profit margin for the 200 - 400 peices? is it enough to cover the 8 - 10 k that you are thinking of spending on the router? If so, I still would sub out the work. The learning curve can be quite high. Some folks get it easily, some dont. Also, a machine in the price range that you are talking about may or may not hold the tolerances that need. IF not, you just blew the money. Subbing it out, can get it cut on a GOOD machine, with tight tolerances.

Certain types of plywood will respond better than others for this type of work. Don't expect to use some OSB and get good results. Look into some Baltic Birch Plywood or perhaps some appleply (brand name) plywood. Decent tolerances can be had form each as they are relatively stable materials.

Subbing out projects like this to me are a lot more than dollars and cents. Vendor dependability, quality, leadtimes, are all very important. The old saying is "speed, price, quality - pick 2" (the vendor usually gets to name the 3rd) is often very true. Often times doing work in house is not a matter of cost, but control over the product. Perhaps that is a better place to start asking yourself questions. Do you need to control every aspect of this project?

On the other hand, if you outsource it should leave you with more time to do other things such as assembly of finished products, marketing, design new products, etc. Outsoucing usually will give you a better "fixed cost" as well.

Sorry for the ramblings, but I've been there done that and have always believed in "doing what you do best and let others do the rest" is a good rule for making stuff more efficiently.

Dan