I don't know enough to say how healthy their business is, but Voyager and Baja are still in business.
True but Voyager makes racks for lots of other Rovers, LR3, LR4, 87-2013 RR along with other products. Some of who's owners are willing to spend more than $700 on a roof rack. If they were trying to stay in business on just DI, DII and RRC roof rack sales it would probably be quite different. How many people do you think are willing to pay 1,000 to 1,200 for a roof rack on their 2,500 DI? I would imagine given the size of their product line they probably use computerized benders which will also help. But can only be done to scale.
Baja Racks is even more expanded and they make racks and products for most major brands of 4x4. It's all about the economies of scale. My reply was to a comment about copying and reproducing the KVT racks. Which would have a very limited market of CAB's. Not a statement about roof rack manufacturers in general not being able to be profitable. You have to expand your market base in order to make money on a small margin item like a roof rack.