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Question about a single-piece manufacturing process [images provided]
Hello everyone, I'm a Mechanical Engineering student and currently working on a design project and need to come up with a recommendation about a manufacturing process or processes, that can achieve the design on the picture as one-piece. I have narrowed a few processes after long hours of research, Extrusion is an option, but I can't seem to find a way for producing the internal geometry of the shell (the tip on the open end). With impact extrusion, a die at the desired angle and an impact tool with the internal shape would be an option, but I will have both ends open. Need to have the bottom end closed, that and the chunk at the tip are my main problems. The material is Aluminum.
Here's a pic of the design with its cross-section:
[URL=http://imageshack.us/photo/my-images/141/crossxz.jpg/][IMG]http://img141.imageshack.us/img141/183/crossxz.th.jpg[/IMG][/URL]
Any input will be much appreciated. Thanks in advance!