I figured the majority of costs related to setup rather than actual runs. It's the same scenario I've been told about concerning custom PCB's. $105 for one board, but $55 each for two boards and ~$38 each for three. Doesn't take a mathmatical genius to figure out what's happening. I was kind of hoping there was something similar to the cottage market of reproduction prints we have for marquees and side art.... of course, I'm not interested in paying $200 for a sticker smaller than 3"x5"

Or like shardians suggestion of Office Depot sticker (if it's a good size) that might give me the possibility of printing it with the toner printer here at work or an ink jet.
It just occured to me to refer to scale modeling techniques and use metal foil. The card backing might be too thick and the foil might be too thin for a printer. Wouldn't hurt to look into that.

you'll pay the same for less stickers if you get me as the materials and running costs of the machine will be negligible in comparison to the set up cost.
You lost me on this point.