Have you considered using a casting?
The initial mold may run about 3k, but after that your per piece may only be a couple dollars each.
Just so happens I do that kind of work.
I design and build the mold (lost wax) and have my foundry pour the metal.
There will be a minimum of machining, hey I can do that too!
PS: Please see my ad in the classified section, here on the CNC Zone