why dont you cnc mill the parts? Ask everyone who wants one and let them mill in one go. I would use Aluminium though, it's cheaper, lighter, doesnt rust and is cheaper for milling because it's softer. I could have told you that 3D printing in metal (laser sintering or casting in a special mold) will be really expensive.The 'prototype' is printed in plastic. Which is fairly rough.
Shapeway is quoting $30/pair in plastic, $190/pair in stainless steel/bronze steel/nickel steel/black steel, and $200 in gold steel. Woweee.. maybe 3D printing isn't the best idea. Anyone know how to cast steel? I can print it in castable wax
If you have a steel sidecover you can use two strong magnets to hold it on the side. Just make a thin layer of rubber under the badge to not scratch anything and two holes on the back of the badge for the magnets.
With this solution you could place it over the screw and take it off/on without changing any adhessive.