I can laser cut these if you like, you would have to mill between the letters.
I can also 3d print them then have them chromed.

Here's a badge I printed...

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  DATSUN EMBLEM 01.jpg (6.67 KB)

It'd be awesome having a plasma cutter available. Where are you working?

Stainless is a bit of a bugger to work with, aluminium might be easier for polishing and like you said Chris water jet wouldn't leave the same tarnish. However it sounds more expensive than I considered and would probably only be worthwhile doing if it didn't require the cutting to be outsourced.

Here you go Finn!

Datsun 1000 Boot Badges

This was not a success becuase:

- it was exceptionally difficult to polish the items after laminating. I used a polishing wheel but a tumbler with ceramic bead would be ideal.

- the laminating process was very tricky because when I clamped it all up the letters would slide and slip.

- the laser cut letters needed a lot of tricky cleaning up because of residual slag from the plasma.

- buyers are somewhat ignorant of the effort to make these so it was hard to get good numbers.

Let me know if I can help.

Water jet cutting does not leave residual mess so it is by far the best to reduce I perfections which translates to less effort in finishing.

The ultimate would be a CNC cut item but it would have to be heavily discounted to go through as a success.

I made some of these up as a laminated set of 2mm and 1.2m. Stainless to get the raised individual letters.

The laminating was done with a high grade adhesive, I even bought a mobile spot elder to try that but the spot weld imperfections are difficult to get rid off (requires a very hard buff/cut).

From as far as I got it was not worth the selling price by the end of it. However if you have access to the equipment it may be worthwhile.

You cannot get the embossed look with water jet or laser cutting. It is only out of flat material (all the same thickness). I've looked into this before.

So has anyone priced up water jet cut badges for rear and quarter panels? Too expensive?
We are getting a plasma cutter at work but it's not CNC, but gave me the idea.