[Help Needed] trying to find best way to etch UFO

[O1OO1O11]

my name is Ben and I am working on a project where we are creating a small UFO model that is machined out of solid aluminum. I need to find a company who can etch the black 'port holes' and ring onto the discs. it needs to be very precise so I was thinking a laser/photo/chemical etch at a depth of .010". I would prefer it to etch deep and clean - that way I could fill it in with paint and the paint would have something to settle in an stick to. otherwise - if I just paint it on the smooth outside it could more easily chip off.

the discs are going to be either 4" or 5". this is a small project with the total number of units made during the first run at about 100 in small batches of 10-20 at a time. i am attempting to keep the cost to roughly $35 per disc for the 6 small port holes and ring to be etched. the picture below is of my 5" prototype:

THE SIZE OF THE PORT HOLES ON A 4" UFO IS ROUGHLY A ROUNDED 3/16" SQUARE AND THE RING IS ROUGHLY 1/16" THICK AND 1 1/2" DIAMETER.




could anyone here point me in the right direction or offer some insight please? anyone know of a company that could small runs at a decent price? i have contacted a couple of people but thought i'd ask you guys as this site has the most knowledgeable members

TIA

[bpoulin]

Here are a few ideas.

1. Vinyl mask and paint, and if you need it to be more durable, you can sand etch the metal then paint.
2. You'll have to research how, but you can use a vinyl mask and a chemical etch but I've never done it so I don't know much about it.
3. Laser etching can be done but you'll have to find someone with a fiber laser. CO2 won't etch metal directly, you can etch a chemical on to it with a CO2 laser using something like thermark.

The vinyl route could be done at any local sign shop. You can probably make your own template draw it out in an art program. Then print it on paper, cut it out, and check it's fit. Once you get a perfect fit, take that art file to the sign shop.