I knew a guy in Brockton, Mass that ran an outfit called "The Hock Shop", dealing in Civil Air Patrol stuff, but I'm sure he could get what you were looking for.
I would also point out that if you live near a large military base, you will often find uniform or surplus stores or tailors catering to the military personnel very close by. These stores often have the embroidery machines to make the name tags. Within two miles of the main gate at Ft. Lewis, there must be at least five such stores.
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