I made a replica Ranger Tab as a birthday present for my Dad, who was a US Army Ranger. The letters are hardwood, a little under a 1/4" thick, and were milled on my Othermill. The outline and back pieces were too large to fit in the mill, so I had those lasercut out of birch plywood.
Recently, I had the opportunity to spend almost a whole week MIG welding. Before this, I'd never spent more than an hour or so with a MIG machine, so it was fun to see my progress throughout the week.