Well 3D printing was the original intent, but apparently that was ruled out.
Yes I meant it would have to be rationalized into a series of developable sections that would be relatively easy to roll into a roughly-egg-like shape…trying to actually form it would be basically impossible for the trimmed-out pattern, it would just come apart, you would have to pound out an egg shape then cut it out.
Well THAT CNC machine might not be able to work with steel, but the general idea is fine. I think it would be too delicate for machining, though, not to mention very large, but I’m sure a high-end machine shop could do it somehow if you gave them an unlimited budget for 5+axis machining, maybe even EDM somehow!
I was specifically talking about that machine.
From what I got from the Greg Blanpied solution, if its to be done with metal, a robotic arm laser cutting would be the ideal solution, but I’m not sure my client wants to go that way.
I’m going to let him experiment, but I’m sure we’ll revert to 3D printing. I think it would work best and has the added advantage of the material scattering light in a more intresting way.
I’ve already marked Laurent Delrieu’s answer as a solution so I’ll try this hypothesis and keep you guys posted about this.
Another production alternative would be to CNC machine plaster molds and slipcast porcelain or similar.