Im carefull not to post too much here, as i dont want to compete with Scott, however, i should speak up on this one : )
>>why are some 5u panels have rounded corners?
No reason, other than a cosmetic choice by the designer.
>>Also is this viable to design your own panel for having Oakley or motm style modules.
Loads and loads of people do : )
>>Plus I would like to have Dotcom style knobs on 5u simply because i like them. Is that possible without any problems I would also like to have better detail around pots/knobs than motm style.
Many people add 'tick marks' but it adds to machine time / cost.
>>Plus the idea of a FPD price for a one off panel?
It all just depends on what's on it. Such seemingly small things can alter machine time (and hence cost) by more than you would imagine.
If you want to keep your cost down with CNC work (ie FPD etc) then keep to single stroke fonts (ie fonts that can be cut with a single cut - not bold fonts that need 'multistroke')
All line work requires cutting
& keep to single infill colours and / or dont infill.
If Scott has the panels you want, and you want to keep costs down, buy from him, esp if youre in the States. 1-off CNC work will never be able to compete on price with bulk silk screen printing. Silk screening is costly for 1-offs, but scales much better than CNC.
For this reason, im not competition for Scott, so ...
This is me -
http://www.thebeast.co.uk/cnc/Im in Europe, so whilst i am still competative with FPD in the States, im most proud of the monnies im able to save those in the EU (generally about 20-25% - which is worth having on a bunch of panels)
One final thing id mention -
Make sure you get someone else to 'proof' your design before cutting.
Ive had stacks of designs in where there have been the odd issue that ive been able to point out the customer. Without someone proofing the panel (be it the person who cuts it, or any peer online) you can imagine the frustration (and cost) that's possible.
Good luck. Its very pleasing to get your own design back, cut on metal, and then to fit it all together, and it work...
Julian