Yeah, I have a friend who runs a business with a CNC router so the cutting of the shapes shouldn't be too bad. Its just the applying of the images that I'm currently struggling to get right.

The stockists are interested in an almost screen printed like quality. Ie printed onto the wood but as you say above that set up required for that is expensive. Think the only way to test it out is to get paper in for all the options you outline and trial. Unless anyone is interested in running through their equipment for me? (I don't have a flat bed press at the moment.)

Think a final coat of varnish/ lacquer will definitely be needed.