Okay, this has done an entire back-flip. I looked into getting these copied and cast but it's turning into a nightmare, I am now making the badges myself running off the original plan of a laser-cut layered format.

I just haven't had the time to chase down mould-makers and most of them are charging upward of $400.00 just for a mould.

Sorry for the slow going, but you gotta understand that there are hundreds of other things going on.

At least they will be much cheaper doing it this way. I'll have another update in the coming weeks. For those who are still interested feel free to show interest, I have a list from 1200.com here so you guys who spoke there I should have your names down already.

Chris

Hi,

Datjas that would be fantastic and very very helpful. Could you explain a little more about the composite?Is it okay to cast steel items in or is plastic better?

Chris

I had another surf after our convo Chris and found there some companies out there that make custom badges...the rates seem pretty cheap:

http://www.decalsmaker.com/index.php?main_page=index&cPath=144

The downside might be they might turn out kinda cheap looking and they have an adhesive backing :/
Theres always Shapeways:

http://www.shapeways.com/

Prints in different materials incl stainless from your CAD file and only charges by the size of the piece...stainless is about  $10 per cm3!
cant be too manyu of those in a badge hmm?...is there a 3D file for the badge floating around?