A basic list of necessary evils:
1. You need a type 06 FFL. ($30 / 3 years)
1.a. You have to let the ATF inspect your place of business, and home, any time they want.
2. You need a business license through all appropriate governing agencies (here, that's State, County, and City). (Cost can be cheap; or astronomical, depending on where you are. Here, it's about $575 over 3 years, plus 3-5 hours driving time and gas.)
3. You need to be in an area where zoning regulations will allow an "Ammunition Manufacturer" to operate. If you're in a city, don't count on getting approval. If you are unincorporated and just need county approval, it will depend on the idiots you send your tax dollars to.
3.a. You need to be in an area where bulk storage of powder and primers won't be an issue. Again, zoning and fire regulations are generally not friendly.
4. You need to be ITAR registered (~$2,500 / year).
5. You'd be an idiot to do it without business insurance and liability insurance (they're separate policies, and cover separate risks). Business insurance isn't too bad, but the liability insurance will not be cheap.
6. To keep your liability insurance premiums "reasonable", you'll need to have each lot of ammunition pressure tested. You're looking at $300-800 a pop, plus the cost of the ammo and shipping.
7. You need to keep DETAILED records of everything you do, and your insurance company may even require you to keep exemplar ammo from each lot produced (more money lost, just taking up space on a shelf).
8. You cannot store your personal powder/primer supply in the same place as your business supply. (I vaguely remember seeing this as an actual regulation, but it may be an insurance requirement that I'm mis-remembering.)
9. I'm probably forgetting 3 or 4 dozen other things...
Bottom line:
Go big, or go home.
(I am not a manufacturer; but I have spent a significant amount of time researching the possibility.)
If the guys at the gun shows are doing this on a regular basis and they don't have the proper FFL they will be in for a rude awakening one of these days.
There were a bunch of guys selling cast bullets in the area I recently moved from. Once the ATF got wind of their lack of 06 FFLs... their advertisements and gun show booths vanished almost overnight. I don't know if they were prosecuted, but they sure did stop selling bullets in a hurry.
Before anyone asks...
YES, you also need an 06 FFL just to sell cast bullets. According to the wonderful legal definitions in this country, a projectile is "ammunition" (even empty, drawn copper jackets are "ammunition"
). Since you need an 06 FFL to produce ammunition, you need an 06 FFL to manufacture bullets for sale (even the lowly gas check requires an 06 FFL to manufacture for sale...).
There really isn't much difference, from a business standpoint, between selling bullets and selling loaded ammunition. You can get lower liability insurance rates, but the rest of the requirements are the same.