I made this at TechShop.
Only use tools that you have had the appropriate training for. Always wear appropriate protection for environment and tools in use. Understand and accept the inherent risks associated with any operation.
Xacto (brand) Knife
Straight Edge (chunk of CLEAN aluminium)
Arches Hot Press Watercolour Paper
Strathmore Coal Black Drawing Paper
Glad Press'n Seal or Scotch Artist Mount (any laserable low tack mask)
3M Super 77 Spray Adhesive
Spray Adhesive for Metal Leaf
Composite Metal Leaf
Step 1: Design
The aspect ratio was chosen to match US standard business cards, but shrunk a bit so the longest dimension is that of a credit card. This is to allow the finished product to reside in a wallet without damage.
Make sure your design has cut marks and fit as many into one sheet as reasonably fit. I calculated that on my first production run each card took 6 minutes of my time to create- That is I completed four sheets of ten in four hours. If the sheets fit 12 I would have reduced that time per card by 20%.