Planning on Cosplaying Dr Weir? Here's my Atlantis Badge as worn by Elizabeth in Stargate Atlantis. As you can see from the reference photo I got this very close. The extrusion is roughly 6 mm, border is 3mm and the overall badge is 7 mm in depth. The overall piece is 8cm in width and has a 5mm recess to keep the material cost down and for somewhere to put your pin or magnet.
Thanks for looking :)