> lay out a panel in AutoCAD (or equivalent) and laser-cut it for you.


I've been watching this discussion of panels for a bit now and just wanted
to mention. I've worked w/ laser cut parts alot. One thing that I've found
is that laser's cut the alum pretty well, but require alot of clean up
afterwards as the alum. leaves alot of `slag' on the back-side of the cut.
One alternative to this is to have is water jet cut [ or hydro cut] this
leaves a very nice edge and is very comparable in price to laser cutting.
I've had 1/2" 304 cut w/ the hydro system and it leaves a very nice square
[ little if any curf] edge that is sorta polished looking.  Laser is great
for both stainless and steel but Hydro is recommended for the alum.

My 2 cents
Jarrett Johnson