Would a billet aluminium blades and boards work?
Would they be stronger?
Would they be lighter?

I'm gonna go out on a limb and say they'd be definitely cheaper. Once you've got the file, load up a blank in a 4 axis cnc mill and basically walk away. Plus polished boards would be frickin' cool. Or even anodized. Might want to make the top removable, a bent board could be trouble if you couldn't pull it out the top......