Embossing

Years ago I worked in the “home entertainment” product industry. To simulate various front panel components our model shop guys used to emboss .020" thick aluminum sheet using plexiglas for dies. You’ll need a “male” and a “female”.

The plexiglas was machined and hand fabricated; hand files and a Dremel tool would work for simple shapes.

Depending upon how complex your graphics are plexiglas might work for you, it’s certainly cheap. They used a simple hydraulic press but a big vice would work as well, provided your pieces aren’t too big. Remember, the larger the surface area of embossment, the moe pressure you’ll need.

An embossed circle would be a good first project.