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It is a very cool design. If you plan on doing a lot of them you could get a cheap scroll saw from Harbor Freight along with a bi-metal blade. They also have a 25 piece domed punch set. With that you could raised or embossed badges.
 
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Did you use a polished sheet of alum., tape a printed sheet of paper, then engrave through it? Did you use a dremel w/bur or a engraver? Thanks!
 
The copper one I etched with the "toner transfer" method, hydrogen peroxide and muriatic acid.

Lots of info online, here's a couple links:
http://makezine.com/projects/pcb-etching-using-toner-transfer-method/
http://www.instructables.com/id/Stop-using-Ferric-Chloride-etchant!--A-better-etc/

The shiny silver badges are nickel-silver, also called German silver. These I had a friend make some plotter-cut vinyl stickers for use as the "resist". The toner transfer method allows bleed-through giving a distressed look, the stickers don't have any bleed, so the edges are crisp and non-etched surface is left smooth.
 
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** Cast and engraved LED **
(Used dremel to engrave a piece of hard wood into the ruff shape of the emblem)
(Melted Led in it with blowtorch)
(sanded it flat)
(Engraved with dremel tool)
(Bend into shape)
(paint and polish)
(Attached with industrial double sided tape)
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DSCN4880.jpg

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OHP you have one steady hand. Every time I have tried to use a dremel to make letters I end up slipping and cutting off a piece of a letter. Looks great!
 
38 Hawthorne TwinBar (BO9 starsNbars)
Before
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AFTER
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