Firstly, regarding this thread in general: OMG YES.
This is fantastic, Nick. Would you be willing to share your vector source files in this thread once finalized?
I have been interested for a while in making up a CAD model for the rack. I think it should be machined, and as I've recently started to get into acrylic machining, I'd be interested to give it a try.
FWIW, my inclination on this would be to laser cut the acrylic and then make up a few silk hasty screens using the vinyl cutter. I believe the originals were probably screen printed (at least the TNG single-layer PADDs). This avoids having to do all the careful peeling (other than just once), and I think it's visually more accurate for this prop.
The edges should also be radiused on a router to be fully accurate.
I technically have the capability to do all of these component processes, but I have yet to put it to the test to build a single-layer PADD myself.
I have always wanted the green and blue ones too, but Jose's over on the TPZ are really expensive. I'll see how the mockups (so graciously underwritten by @kertratz) come out. Otherwise, I might want to figure out how to make those too. I'm a huge Crusher prop fan.
Have you seen @kertratz's excellent VOY Pathfinder PADDs? Aaron: you should do a thread on how you had those made! I'd love to know the details of how you went about that. I truly cherish my set.