>>2792209
>3mm (11 gauge) piece of steel

That's going to be tough since the material is so thin, it will easily get bent or warped from manual operations.

What I would initially try is glue the sheet metal to a backing material like mdf board. Print out a 1:1 scale drawing of the thing and glue it on top. Cut out the external shape using a manual jig saw. Drill a series of holes along the slots and use the jig saw again to connect the holes and then use a dremel to grind the edges to the right shape.

It's important while cutting to make sure your saw blade cuts only on the down stroke so that it doesn't try to lift the metal sheet off the wood backing. Heat the metal up with a blow torch or similar when it's done to destroy the glue and separate it from the backing.

Or avoid all this shit and find a sign shop with a CNC router.

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