kolosy:
Have you guys run across shops that do one-off CNC aluminum parts for < 50 bucks? Shapeways 3d prints steel, but it's pricey and heavy.
It doesn't seem to be so much as steel, as "steel powder infused with bronze"; I'm not sure what the final strength of it would be, or how it would compare to a machined billet aluminium based part.
I tend to doubt that you will be able to find a vendor doing 1-off parts CNC machined from aluminium for under $50.00. Most machine shops run on an hourly base, generally minimum of 1 hour (or of "x" parts); then you have setup of the machine, operator time, etc (this will be built into the final price usually).
For singular parts, a shop would be losing money and won't usually take on such a project. Sometimes a shop will, if you are local and willing to wait for a "downtime" moment in between their standard runs (but such shops are rare, I would imagine). Most shops will just laugh and show you the door.
Your best bet might be to find a local hackerspace or similar, and either use their equipment or find someone there who is willing to do it. Just don't expect instant results.
emachineshop.com will do that sort of thing. But again the problem is getting low pricing for single parts; if you need like 20 or so then things get more reasonable.
IMHO your best bet is a drill press and angle grinder or hacksaw.
kolosy:
I'm running into a need to get smallish parts CNC machined from aluminum. The strength requirements are such that 3d printed plastic isn't cutting it.
Have you guys run across shops that do one-off CNC aluminum parts for < 50 bucks? Shapeways 3d prints steel, but it's pricey and heavy.
Try uploading your part to firstcut. They have surprised me a few times on how cheap they can be.