ive put much thought and effort into mass producing reliable ammo that is cheaper and tougher than a potato
plastic ammo would be the most possible option that i can see, it could be produced cheaper and faster than potatos, if the bullets were rifled it could be a cheaper way to get better to accuracy than a rifled barrel with spuds.
im offering these slugs for free (well not really, you pay for shipping) to test the strength of different polymers. The only deal is that you gotta have some way of recording a video of the impact and tell me how they shot. I got a bunch here is a pic of some of the basic types of plastic ive tried.
some of the slugs came out kinda crappy, but if you notice i progressed each time from left to right on each plastic type.
from left to right:
the three white slugs are Polycarbonate, the one leaning up was shot at a tailgate of an early 90's full size Chevrolet over a dozen times (notice the red paint), also blasted every headlight/tailight out of a totaled 2002 Dodge neon along with another dozen shots to the door panels. No cracks or dents, just a little mushroom on the end. I honestly dont think you could break this material using plywood as a target... hmm.. reusable ammo maybe?
The clear one is also polycarbonate, except since its clear they call it lexan (lexan is simply a "brand name" polycarbonate plastic)
The three grey ones are rigid pvc (same kind in conduit pipe)
the three orange ones are nylon with a flourescent colorant added to it, those were the hardest to mold as you can tell from the quality but the color of them makes them easy to find.
The white one on the end is made from 4/6 fiberglass reinforced nylon for use in high strength applications.
and the cannon used to fire it was this:
