Styrene disks

Harbor Freight Tools sells a punch & die set which should cover the sizes you need

http://www.harborfreight.com/9-piece-punch-and-die-set-95547.html

Go to Lowes/HomeDespot and get a couple of plastic No Trespassing signs.    They are about 20 thou thick.    An hour with the punch & die set will generate all the disks you need

I was thinking of punches myself. You could also try some craft punches (the kind my wife uses for scrapbooking). They punch out .010 styrene very cleanly. They don't come in the smaller sizes, though.

Also, a quick look on Amazon reveals some options for 3/4 inch and 1/2 inch discs. A more thorough search should give you some more options. HTH

There are punches available as a hand tool.  Sort of like the punches that conductors used to use to punch out your ticket, but they have a wheel with several punches of different diameters, and they punch styrene sheet very nicely.  Some of those punch several sizes up to 1/4 inch.  For larger sizes you need a punch set, different punch for each diameter.  It doesn't take much time nor effort with either style of punch.

I have one of those punch wheels. While they work great for leather work (which is why I bought one in the first place), I have found they leave much to be desired when it comes to plastic. In a nutshell, the cut out disks get stuck in the punch and are almost impossible to dislodge in the smaller sizes and it's not possible (for me, at least) to dislodge the larger ones without deforming the disk.

Thanks, I just bought a punch set identical to the one pictured off eBay. Thanks for the tip about the plastic signs too, but I have so much sheet styrene, it's taking up too much space and getting in my way!

I keep several pieces of rod of different diameter handy to push out the disks I make with the hand punch.  How easy they are to get out may depend on the brand.

I have found that you can use craft punches with the round tip in many sizes .There are limits to the thickness though .Thicker stuff gets the punch set shown .

I have a set of gasket cutting punches that come from 3/16th ti 3/4 inch in 1/16th increments., The are designed to cut soft material like leather or gasket material and they will cut styrene  up to 1/4 inch with no problem . You just need a solid wood block and a good hammer to cut out your disks. I use mine to make brake rotors and flanges and all sorts of round flat things

carl

I have both the wheel and a punch set.  The wheel does smaller disks, the punches the larger ones.

 If you can stand a hole in the middle of the disk, sometimes I cut a number of disks to rough shape, drill a hole in middle, and stack them on a Dremel mandrill.  I then chuck it in the dremel, and use needle files or sandpaper to round them off, a bunch at a time.