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I've done some research and not had much luck. I'm looking for a place that makes custom speakers grilles. I would like them for both my mids and subs. I'm thinking something like this http://www.parts123.com/parts123/yb....~Z5Z5Z5~Z5Z5Z5
if you can live with having them built from acryllic or other plastic then look into laser cutting (there are places online that will do this for cheap)
that i have no idea about. Its materials and the materials needed for trial and errors and the guys time and equipment use. You tend to think anything is possible, but at what price. May be worth it to you, may not be. I would try vrumvrum and see what he says