That's interesting about the relative recycling value of chips vs. blocks. Is it possible to keep the chips covered in coolant to prevent oxidation if it is known that the aluminum is going to be remelted?
I had a look and found this: http://www.ars-inc.com/ROI.htm
Still, buying expensive aluminum billets and then turning ~99% of the material into chips as would happen with a case design similar to the current MBP wouldn't be very efficient.
Perhaps they are moving to case designs that are a combination of CNC machined parts and stamped pieces? I'm sure Apple's design team is a lot more imaginative than me. There are some CNC-looking parts in the current MBP like the bracket that fixes the HD in place.
But let's face facts. Steve will not rest until he is selling Cube shaped computers again. :)