Cricut Machines for Etching Stencils? - Glass Etching Secrets
You load vinyl in the machine and it will cut out fairly intricate designs. They cost around $300, but you can get them on eBay for a little less. Just thinking of going that direction. I was looking at SCM and their photo stencil maker, but it is $700. Although you can turn any photo (just about) into a stencil.