If you're only going to sell a few hundred of the "Studio 60s", you might skip the mold and 3D print the enclosure.
My printer can only make horns that are 6" x 6" x 6" so my results aren't ready for prime time. But if you guys bought a proper 3D printer you could print the entire thing.
There's some other advantages to 3D printing which aren't immediately obvious:
1) You can achieve absolutely insane tolerances. For instance, when I went from working in wood to working in 3D, I was able to "pack" the drivers much tighter together. This is important for a Synergy Horn because it allows you to optimize the response in that critical midrange octave.
2) Synergy horns have a TON of fasteners in them. For instance, an SH50 will have nearly a hundred. This is because there are so many drivers, and all those drivers have mounting points. When you print in 3D you avoid the drudgery of drilling a zillion holes for that. That might sound like a small thing, but it's not; when I've assembled Synergy horns I sometimes spent an entire day just screwing everything together and wiring it.
3) With a 3D printer you can offer a wider variety of options. For instance, you can easily offer a cabinet with 40 degrees of coverage and another cabinet with sixty degrees of coverage, without making a mold for each.
4) You can print your own phase plugs. This allows you to do things similar to what JBL does with their midrange compression drivers.
It looks like there are 3D printers that are capable of printing a SM60F for under $5000 : http://3dmonstr.com/?q=3DMonstr-printers