A few reasons for the lack of response ...
There are many machining operations for which Ti works well - outside turning, profiling, milling, etc. On the other end of the list are deep drilling, tapping & (you guessed it) knurling. IMO knurling is even more difficult that deep hole drilling. Many machinists have one or two form knurl tools like the one shown below:
The orange arrow points to the steel axle pin around which the knurl wheel rotates. These have inadequate strength for Ti work & are replaced with solid carbide pins. Even with that mod it is extraordinarily difficult to cause Ti-6-4 to cold flow into the knurl wheels. A much better tool (and one owned by a few machinists on CPF) is the cut knurler shown below:
Lower machining forces mean a greater likelihood of a satisfactory result. If someone runs this tool all day every day it's easy to get great results in Ti-6-4. If this tool is used once or twice a week the set up time is a killer - figure at least an hour's labor plus quite a few inches of bar stock at $8 USD/inch. Figure the cost of the cut knurl tool at $1000 USD & you can see where this is going.
Even if all that tooling & experience is already in place (& it is not in my shop) the body has to be knurled while the bar stock is solid, before it is bored for the battery. A knurled surface looks good & feels good but is far less than perfect for the next machining operation.
There's someone who'll make this for you. Rough guess is that the cost of a full knurl light is twice that of any other surface profile
Try contacting
Photonfanatic (Fred). This is exactly the sort of thing he does.
Fred would be my first choice but he already said his machine isn't set up for this. If I had the cut knurl tool I'd be happy to knurl the bar stock & send it on to Fred or anyone else who whoud finish the build but a $1000 USD specialty tool isn't in my budget.
I don't have CNC equipment but some machinists have had success using a 4-axis mill for helical interpolation to generate the pattern. Imagine a pair of helix profiles that meet at the correct angle to make the pattern. Cost effective if you need 50 parts or more :nana: