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Hi Andrew,

Not sure on the shapes you are thinking of, but wondered if it would be possible to use a press and stamp them out. You need to make the tool, or have it made, but then you could make...

Abrasive water jet is a very high velocity squirt of water mixed with grit. It will cut through most anything, without heat.

Depending on quantity, what about water jet cutting?

A laser is that quick it wouldn't damage the coating, we have it cut in 4mm thick and it still leaves the clear plastic sheet intact.
cutting alloy, especially in thin sections with a router is...

Holding it is your problem, it's too light.

You could use left hand helix to stop it burring up but you'd have to change the backing about once a sheet.

Have you been put off by a laser...

Welcome Andrew

Are you looking to build or buy?

The first obvious problem is that you will need to cut all the way through in one go so a sacrificial bed will be needed and probably double...