Well the font on this one made it difficult. I don't think many casting companies would have used this font .. some of the features are just way too thin. I had to fiddle around with various aspects of the font outline to make it suitable for printing.
I've pretty much got the printer settings down now so I don't have to spend hours printing out test pieces. The modeling would be fairly simple on the typical badge. This design was created from scratch so a bit more complex. No existing example of this dealers badge was to be found. So the owner and I based it on typical stuff of the era.
Downside is everyone would probably want a different dealer, so the modeling would have to be redone each time ... unless it was a really big dealership

Wonder what the Royal Pontiac badges looked like. Printing time is about 2 hours each.
The car owner in this case was quite generous and sent me a surprise donation for the effort. Much appreciated.