Try photo etching - usually very reasonable, and minimal waste.but
there is always some waste. Works better for thin sheet.
Another option, depending on scale, would be to have a cutting die
made - try contacting Dar Shelton at Shel-Tech (sp?) for this
service, unless you want to face the learning curve by your lonesome.
Then just use a press to cut them.
And three more - laser cutting - super thin kerf so minimal waste
but relatively expensive for machine time.
Water jet - wide kerf, but usually less expensive machine time and
fast (may want to get a quote from a water jet company, I've found
them less expensive than plasma cutters).
Wire EDM - Super accurate, relatively expensive.
Chris Ploof Studio