Alternatively, how can these be made using off-the-shelf supplies? I do have access to a laser cutter.
I found a general description of one process on this site:
http://www.primeproductsinc.com/cnc-las ... ansas.html
The materials used:[...] the overlay and PSA backing were laser cut on our CNC CO2 laser, with spray paint applied in our spray booth with a fine-detail spray gun. The overlay was also fiber laser etched on our Ytterbium fiber laser, the finished overlay was also oven baked and cured, then assembled.
Lexan 8010 clear film, polish/polish/ 0.20"
Black ADE52 (Epoxy screen ink)
White NAZADE75 1K (Epoxy screen ink)
3M 9690B (double-sided adhesive)
"Proprietary dead-front paint system"
"Clear matte polyurethane mix"
My deduction: since the Lexan 8010 film is polished, the clear matte poly gives the matte appearance on the front side. The back side has 3 or 4 layers.. the non-graphics areas seem to be black epoxy ink backed with white epoxy ink. The graphics I'm not so sure. In the back side image you can see reliefs around the characters, revealing either black epoxy or the dead-front ink. How is this layered?