You can use a router to trim aluminum (depending on the grade and thickness). What I did for my amplifier mounting pads was to cut the aluminum as close to the actual dimension needed then I made a jig and followed up with my router, taking 1/8" or less off to the actual size. Then I cleaned up the edges and polished the whole thing. This only works for flat parts, if you want something 3 dimensional then yes, you'll need something machined.
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