Check out Don Lancaster's site at www.tinaja.com.  He has written
several times about the photometal process.

I personally silk screen mine.  It is easier and costs less than you
might think.  I can post a tutorial if enough people are interrested.

PJH wrote:

> PICers,
>
> Following on from that thread about
> stick-on PCB patterns, has anyone
> got ideas about producing "neat"
> looking front panels for project
> boxes. You used to be able to get a
> sort of photosensitized aluminium
> sheet. Can't remember the name.
>
> The idea was you made a
> photographic (-) & put it over the
> panel, gave it a blast under a UV
> lamp, developed it somehow and  the
> exposed bits stayed on. It allowed
> you to produce a reasonably
> professional looking panel with
> printed labels for switches,
> buttons, logo etc.
>
> Haven't seen anything like that in
> the electronics shops for years. Is
> there anything on the market that
> might do the trick?
>
> Cheers - PJH