Quote Originally Posted by mocha View Post
You don't mention if the designs are simple or complex, but have you tried the band saw / jigsaw or sander type route?
The issue with a bandsaw and difficult to cut materials is new blades will cost about £6-£8 and may not last longer than much cheaper blades for fret saws.

I didn't have problems when cutting 5mm thick copper on my CNC router, but maybe I just got lucky.

Roughly many of these broaches is your wife making? If they're all different shapes then a fly-press wont be cost effective, but getting them laser/plasma cut might be? If you do cut them on a router you're in danger of making her redundant as the router can of course do all the engraving...