CAT in Eugene is now making custom fenders. I think Aluminum.

I don't know if they ship.

http://www.catoregon.org/

I don't see them listed on their website, but I know they make them.

I have one vintage bike that I was going to outfit with fenders, so I have some taken off of an old (free) Raleigh frame. They'll take some work, but they should clean up nicely. Anyway, it never hurts to look at used/vingage.