I have been working on a few different ideas about gun design etc. and have gone back to the drawing board with the actual design of the BB. One thought that occurred to me was the method by which shot is made for shotgun shells (here is an article): http://en.wikipedia.org/wiki/Shot_tower
Basically molten lead is dripped through a tower, where the aerodynamics of falling creates a sphere and hardens on the way down. Once at the bottom it is rapidly cooled by hitting a body of water.
Hitting the water would deform thee shape slightingly thus ruining th bb. You'd want a metal which would harden about half-way down the liquid so it could form a perfect sphere again.
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