Posts: 1,278
Threads: 44
Joined: Jul 2007
The best ways to make overlays is to laser cut them. There are usually plenty of places you can find around that will take a pdf or dxf and run whatever material you like through a laser CNC mill at a very cheap price. They usually charge a setup fee (which you can often get them to waive with a little sweet talking) and then time on the machine. For a bit of plastic or paper, it is really quick.
If you can't get a lasercutter, the next best is a little die press that has formed edges to cut it. You just can't do small radii.
TW