If you wanted to do heat fusing you could use powder coating powder instead of toner. This can be purchased around $15/lb. and even less in bulk. Any color you want
Never looked at powder coat - is it a plastic (in particular - a thermoset plastic)? For some reason I had it in my mind that it was metal of some sort...If so - that would pretty nice, especially if it is a fine powder (toner is a very fine powder - and not something you want to inhale); the powder would have to be of a particular granularity to avoid scattering the light too much.
thanks, although i dont know which will provide better qulaity, a laser or inkjet?