Instead of cutting them out on cardboard and only get is few uses out of them before they are soaked through and no longer hold there shape, I figured I would go a differnt route since I was a member at TechShop.
What you need.
1.Material. I chose some scrap plexiglass that was laying he shop.
2.Your design drawn up in a vectoring type format. inkscape, CorelDraw, Ai
3.Access to a laser cutter/etcher.
I made this at TechShop. http://www.techshop.ws
Step 1: Draw Up Your Design
Some cutters have different requirement for line cuting and etching. Be sure you consult your manual.
I had already taken the Class at TechShop that shows you the basics.
Step 2: Set Up Your Material in the Cutter
Step 3: Line It All Up and Hit Print
Step 4: Finished Product
Only thing left is to give it to the scouts to use.