The durability we're looking for is somewhere between aluminum and balsa.
For the contours we're going for, the mechanical engineers and product folks we've been working with have assured us that we couldn't get away with stamping. It's pretty much die casting or milling. The numbers we've been getting for die-cast tooling just don't work out for the scale of production run we're expecting. I'd love to be wrong about all this.
The interior "key plate" and the bottom plate of the enclosure will, of course, be stamped aluminum.
Black anodized isn't the look we're going for but yes, there are a number of things we could to to differentiate it while sticking with the aluminum.