I had the Titanium and Sorbothane parts cut by "WaterJet". WaterJet cutting 
uses a ~0.030 inch stream of water flowing at 1000 meters per second powered 
by a 40 HP motor! This thin line of water can slice and dice almost any 
material with ease. Water is forced through into a thin cutting stream and 
garnet powder is added to give it "bite". The stream is only 30 mil wide, 
but it has say 60000 PSI behind it from a 40 HP motor/oil pump/water pump 
combination that speeds it to 1000 M/s. This water stream can cut up to 
like 8 inch thick titanium and just about anything else given time. The 
advantage is that it uses no heat and the damage to the material being 
cut is nil. The stream is just water and the force on the material being 
cut is maybe 2 pounds. It is basically an X-Y cutting process. Excellent 
at cutting 2D materials out of sheets. Accuracy is within 5 mil in some 
cases but I go "rough" since it is not real important here and rough is 
cheaper ;-)

For the 6-4 titanium parts, it could cut the odd shapes and holes to great 
accuracy (compared to me and my cobalt tipped hacksaw blades and drill 
press) with ease. The cost of the fancy WaterJet cutting was nothing 
compared to the work involved in my doing it by hand!! The parts only 
required minor sanding and hole size touch up and they were all done! 
There really was no other option.

It is interesting that the Sorbothane parts ended up getting WaterJet cut 
too! Sorbothane is a strong sticky, almost chewing gum like material that 
I use for "tread" on Ti-Tan!!. High tensile strength, 600% elongation, 
sticky like gum... Based off the tread on the A1 Abram's battle tank, I 
need 1/2 x 1/2 x 1.5 inch blocks of Sorbothane. I originally had all kinds 
of great ideas about machines and devices to "chop" the tread with blades, 
shears, and all. With 1/4 inch material it was "rough", but ALL the "ideas" 
failed when it came to the 1/2 inch final material. The thick Sorbothane 
just stretches, sticks, squirms... far too much for any simple cutting 
techniques. Accurate cuts in the thick material are done only three ways. 
Freeze it in LN2, high speed electrodynamic cutters that chop it in a 
millisecond, and WaterJet ;-) LN2 is just funny, you get the Dewer and 
Styrofoam box and freeze it. Then pull it out and cut it with a band saw. 
Of course, the chips thaw and clog the saw, and you kick over the LN2 in 
the suffocating mist.... This high speed chopper chops it so fast that it 
never knows what hit it, but not a machine normal folks have or could make. 
The WaterJet was perfect and it paid for itself since it did not waste 
material. My 1/4 inch tread had about 50% waste!! My attempts at the 
1/2 inch were a disaster and it was "all" waste :-p But the water jet 
just sliced the puppies out perfectly!!

I can strongly recommend that folks check out WaterJet cutting! It is a 
wild technology that has vast untapped uses. A definite "must see"!! 
Colorado WaterJet is our local place here.