pjohnson, two issues:
1. Your laser cutter guy probably quotes a minimum quantity based on the size of aluminum sheet he has to buy. What say you go to a metal supplier who sells remnants, buy a smaller piece, then have your guy do as smaller run ???
2. I would not worry about your design being too close to someone else design, this item would never receive a patent, too common, produced for too many years.
Patent Gee Whiz information: The reason Downey never patented anything was; not only was it too easy to get around a patent, but there are companies who would intentionally copy a patent. They would sell 3 million dollars worth of the product, convince the judge they sold 1 million dollars worth of the product, give the patent holder the 1 million, and they keep 2 million in their bank.