If you go digging, there's a thread where someone was concidering it and contacted either Wilsonart or Formica about the process.
From what I remember, the cost wasn't out of line with having custom artwork done. But keep in mind you'll have to buy a full sheet of laminate whether your artwork covers it all or not. Last post by the member in question was looking for others who wanted to go in on the order, several custom control panels would fit on a 4'x8' sheet.
Not exactly sure on number two, I'd assume it would depend on the graphics. Quality should be first rate as either company has quite a bit of experience doing this. I'd suggest talking to Wilsonart/Formica directly, they'll tell you up front what works and what doesn't.
On question three I'd laminate the panel first and drill/route it afterwards. I'd also include centering marks for drilling in the artwork.
The artwork is buried in the laminate as it's being made. Laminate is a combination of phenolic resin and paper, so adding a graphic to the top paper layer isn't that big of a deal. Durability and scratch resistance should be the same as standard laminate. You can scratch it, but you'd be hard pressed to accidentally scratch it deep enough to effect the artwork.
Since you'll have to buy a full sheet anyway, you could always have a backup made at the same time. That way if you bugger up the first one you're not completely screwed.
