http://www.engadget.com/2010/05/25/parrot-ar-drone-to-get-official-launch-price-street-date-at-e3/
Engadget article on the Parrot.AR "Drone" - launching at E3, an interesting venue choice; especially considering they now have an Android client that they showed off at Goole I//O. Clicking the picture above will take you to the Slashgear article.
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AR Drone for sale
Sounds good. My understanding is that ducted blades can provide more stable flight with a bonus of additional saftey. Since I am primarily interested in flying a DSLR and other instruments, the more stable the better.
I have a rather large CNC machine (usable 4x4x2 feet) that I would happy to use for the "cause". I plan on building a couple quad copters in the near future myself.
I think there are a couple options for cost effectively creating the foam pieces. One option would be to mill the foam per order (milling foam is like milling butter) - not ideal but for small volume could be the most cost effective.
Another option would be to mill the original, and cast cement molds of it that could be used to expand the polystyrene. This would be much less expensive than milling billet aluminum.
Yet another option would be to mill the mold out of foam and then cast it into aluminum using the lost foam process. I have a capable foundry and experience to cast it.
Attached is a picture of my mill.