Update: We are now cutting all of the headbands with water jet cutters. This has reduced the time to around 1 minute per headband. Heating the band in the corner with a good heat gun and then laying it on top of a template (or existing completed headband) and then dabbing it with a wet paper towel works great to form and set the plastic and one person can keep up with the output of one water jet cutter. I understand this is a large piece of commercial equipment but you would be surprised how many there are in use in industry. We are reimbursing the companies a small amount to offset their garnet (the abrasive consumed by the cutter) cost.

You may want to reconsider using ABS for this project. It releases Cyanide when laser cut! It also has a tendency to catch fire, and to keep that fire going.

I hope that it helps some people out!