That's quite a task Harvey, but it isn't impossible..just takes time, effor t, dedication, and some money thrown at it would make it quicker and easier ..
Trying not to adopt the latter element, there are probably four of more way s to make the badge.
If you could get an original one you could easily have male and female pres s tools made from it, by casting, possibly in bronze as this material would be strong enough to press quite a number of badges using annealed thin gua ge brass or copper..or aluminium. It would be interesting to try to make to ols, just to run off a couple or so badges, using cold cast polyester or ep oxy resin as the die material. Alternatively with an original to work from tools could be made from composite materials, such as hard resins, and the female form could be used as the tool on which to deposit copper and nickel by electro deposition...like those replica leaf broaches that women used t o wear on their Sunday=-best jackets.
Repousse technique ie the beating of thin non-ferrous metal into the design , using a bowl of pitch to support the metal plate.. this would be done fro m the reverse side first in rough, and then the metal badge would be turned over and set in the pitch and the accurate definition of the badge picked out by chasing with very fine tools. very skilful..but not at all impo ssible particularly with the aid of watchmakers googles to magnify the work place.
Casting would be another form of obtaining a badge, assuming that you can g et your hands on an original one. Dental plaster of cuttle-fish bone could be used as the mould. Some one whom I think is associated with this List ha s had a hand in reproducing those bronze Hetchins badges that turn up from time to time. This is of course would be handy if the original ones were ca st.
Assuming the originals were in plate copper or brass or aluminium, it shoul d be possible to make a mould from the original by spark erosion., or deep engraving,.followed by some press work.. Finally, for now, assuming that the original is low relief brass or copper or even aluminium, like some of the later Hetchins, ie almost flat brass plates, this could be copied easil y by photo-etching. All you would need for that is either a good photo to s cale or accurate artwork.
If you can get your hands on an original or a photo so that you know what y ou have to try to make, I would take it along to a silversmith in the first instance. These days such smiths are trained in multia-medi processes..and they should be able to master repousse, casting, electro-forming/plating a nd engraving. When I get a little time later today I will send you a jpeg of my own headbadges made by photo-etching, of stainless steel. If of cour se the badge is to be in brass or copper, the etched relief could easily be enamelled.
Norris Lockley..Settle UK