I don't know that the cost would be prohibitive. Consider this for a mo... if, purely for the sake of argument, it was proven that spheres of exactly 9.63mm flew much further than other spheres, because of some bizarre interaction between sound and air pressure, how expensive would it be to make BB's that size from scratch? Come to think of it, who decided on 6mm, why, and how expensive was it to make the first machine? How about golf balls?
All it takes is the R&D to prove that dimpled BB's are sufficiently better than smooth ones to be a probable sales success and investment capital. How would they do it? I suppose that, since good quality BB's are polished to achieve their uniformity, the 'blank' would be injection moulded with dimples and the surface polished to remove any defects, just as now. Does it matter if the interior of the dimples is as highly polished as the outer surface?
Since it is the reduction in drag created by a turbulent layer of air sticking to the dimpled surface in flight which is responsible for the effect, it's likely that the interior of the dimples need not be as smooth as the polished surrounding surface. The crucial piece of information we need is whether the effect is scalable and, if so, in what way? Would miniscule dimples, the same relative size to a BB that those on a golf ball are to it, produce a similar percentage drag reduction? If so, I'd bet a bollock that, if any loss of FPS was noticeable at all, it would be more than offset by the better drag coefficient.
I have to say I'm confident that it would work. Maybe the effect will not scale so the drag drops in the same way, but for the sake of retooling an injection mould, even if it only gains us 10m I'd say it was worth it. If it does the same for BB's as it does for golfballs then double the range would revolutionise the sport! What makes me confident is that fighter jets have a surface applied to their bodywork which is like synthetic shark skin and has a microscopic grooved profile - if microscopic grooves are worthwhile, microscopic dimples should too, right?
Personally I don't have a jeweller's loupe or a drill bit tiny enough (which is always going to be the hard part), but if there's anyone here who is, or knows, an engineering student, a university workshop is what we need...