He used litz calculations applying modifications to an existing known BC which i've seen referenced as being pretty dang accurate in the past. My takeaway/assumption is that it just wasn't a high form factor design. Even the DTAC isn't a "peak" form factor type design but was clearly better than this custom bullet.
I also wonder if some of these completely optimized form factor bullets dont end up pickier. Seems like lots of people have reported struggles with the 110 SMK for example and that's a pretty sleek mofo.
I am not an aerospace engineer. I can only speak from my anecdotal observations. I have shot several thousand dtacs. While lot to lot variation is a complaint I have, they are not picky. I can get them to shoot better than most bullets and occasionally as good as Bergers. I think this is a product of manufacturing qa/qc, not the design itself. I have had lots where every group was sub 3/8 moa for 5 shots, pretty much regardless of load. Others were a struggle to get 5/8 moa for 5 shot across several groups. I have had bcs true out from .585 to .635 at speeds from 2950 to 3190. I have never had situations where groups were consistently over 3/4 moa for 5 shots like I have with questionable lots of Hornady bullets.
I have had the best luck with easy accuracy with length sorted 105 bthp, 107mk, 108 berger, dtac, etc. Secant ogive bullets have been more of a struggle. I would personally give up bc for significantly better precision (and I have done this many times.)
It is possible that an optimized form factor 117 or 120 could be tamed by experimenting with reamer dimensions. It is likely this bullet would be a niche bullet for large 6mm cartridges. I doubt it will go fast enough in anything smaller than 6 creed to take advantage of the bc, and even that is questionable. Given that the big 6s are completely custom jobs at the moment, it would be nothing in the grand scheme of things to do the r and d on the reamer to make it work.
Ther is also the possibility that the easy button of no cleaning ect would not also mesh with the best reamer design for accuracy, so there is that trade-off.
Also, for Hornady to make an accurate optimized form factor bullet, I think they would need to run the lots like the a-tips, but use the polymer tips. That seems to be the way to get consistent bullets. When watching Berger factory tours it appears all of their bullets are done in a similar manner. They probably also do more testing, they don't sell seconds, and their bullets are less $$$. I'm not dogging on Hornady. I shoot their bullets for hunting, or if I want a cheaper bullet. However, if they could figure out a way to be price competitive on a premium line of bullets with Berger, they would own the market. I understand what's in play with cost of marketing, r and d, production capacity, etc.
Also, a lot of the market that is interested in this bullet is going to want to play in NRL Hunter. A lot won't, but a rule change could sell a lot of these bullets. Currently, a lot of 25 cal bullets are being sold to the nrl hunter crowd and those copycatting what they are doing.