Anybody have any idea how I can make imitation bronze plaques?
Perhaps using bronze powder.

I have a laser and a mecanical engraver and we are considering a product that would require me to make 50 -100 per week in a quick and innexpensive method.

Would the products be identical, as in something you could make with a single mold?

I don't know how expensive or what finished sizes you'd need, but IKONMetal is definitely a machineable material that could imitate a bronze casting.

I done some custom awards made by PDU. Continental trophies has a program where they make custom resins (smaller quantities).
PDU is very helpful. Original order has to be no less than 500. Tournaround time 3 month. It's only the first time it takes this long. (new mold, artwork etc) after that it should take less time.
Let me know if I can help you in any way as I have done this now 3 times. Hope this helps a little.
Have a nice day
Rolf

There is a very easy way to do this.
You make a master using the laser or the Rotary engraver.
You make a mould from this using 2 part room temperature vulcanising silicon. This is your master mould.
You can get a huge amount of mould making details from the ppl that make the RTV silicon. Google is your friend~

To make the faux bronze plate is easy , It's called cold casting method.
You mix Bronze powder and casting resin to give you a metallic sludge which you paint on the inside of the mould to give the surface a metallic layer When that hardens and is thick enough , fill the rest with something cheaper.
The Plaque is now bronze and can be polished , antiques , patinaed just like bronze can. Often its cheap to fill the back of the Plaque
(you only painted a thinnish skin inside the mould) with lead or iron shot to give it weight.
You can do this with other metal powders as well.
Pretty easy to run 150 a week from the mould and its pretty easy to make the masters too.
There is a thread in Sawmill creek where masters are being discussed , for spin casting.

Wow!! Thanks for all your input .

I will need to make plaques:

1. approx 20 square inches
2. each one different

I am not sure about Iconmetal because:

1.the gold looks much duller than the bronze
2.I think it will take a half an hour to engrave

Do you still think Ikonmetal is the way?
Do you think that bronze cold casting will be quicker/more cost /labor efficient?

If each one is different , the casting method is out.
You can etch brass with ferric chloride and use the laser to make the resist and once etched , then chemically bronze it.

I am afraid of this process. I am afraid of the chemicals and health hazards. Do you think I am being overly scared?

I also need to be able to sell thes for between $25 - $35 each

Cant I cut out a mold from 1/16" plastic, put a frame around it and cold cast it?

No methods metntioned will make you money on one off plaques of 20" sq if you sell at those prices. You want at least 5x material costs as a selling price leat alone labour. You might as well just do it in perspex and paint it to look like bronze.
Google "Faux bronze" for precise instructions how to do the paint finishes.
In terms of etching , ferric chloride is nothing like as dangerous as acids , in all likelyhood the only problems you might have are staining your hands and clothes orange.
If you do master Etching, you will have a lot of other applications for it , like doing stainless steel etc.

the resell should be around $60.

I think that if I am producing 50 -100 per week my labor cost will not be so high. I am guessing that my material cost should be around $5

I can't remember how long it took to engrave the small piece in the photo. I know I had to run it three times with my 30-watt laser to get a reasonable depth. I actually should have run it one more time.

A higher-powered laser is the tool for this substrate. Routing may also be okay if fine detail is not required.