Back to the topic at hand...
I tried something this afternoon that seemed to work...
I have an Epson inkjet that prints photo quality pictures. I put in some Epson glossy photo paper (a LOT thicker than regular paper - almost like light cardstock) and printed a scaled Bantha skull emblem on it using Adobe PhotoDeluxe at the highest resolution I could (1440 x 2880).
The picture really *was* photo quality, and you couldn't tell that it had been printed. I cut it out and glued it to a scrap piece of Sintra using 3M Foam Fast adhesive spray. After it dried, I sprayed Testor's Dull Coat matte lacquer on it.
I looks pretty good! It's a cheap way to go, too! 
I may do this "for real" on my suit. 