I wonder if it's possible to 3D-print titanium mail (aka "chain mail") at a competitive price? Titanium is great stuff for high-end mail, strong, lightweight, shiny, and corrosion-free, but it's even more insanely labor-intensive than ordinary aluminum or steel mail, especially if the links are welded or riveted for strength; prices appear to start at well over $2000 for the equivalent of a T-shirt.

I think you'd want to print it in a sort of collapsed/"wadded-up" form, to reduced the print size and to insure you can get enough separation between the links that they don't bind together. You'd need some pretty fancy algorithms to translate the client's measurements into a wad of printed mail that will be the right shape/size when spread out, but once you got that down you could just plug in the numbers and watch it go. If you could get the price down to something decent, I think you'd get a lot of business from SCAdians/fantasy fans/etc.