Thanks for the info guys!
The paint over BMF method I have seen before, I have a couple of concerns with that method however, the first being that I will lose definition with such small parts, the second being how to make the edge of the BMF appear flat under paint.
The whole motivation behind this is to make the badges appear more 3D, as if they have actually been stuck on. I guessed the best way of achieving that is to actually stick them on!
I gave the foil casting method a shot last night, made two foil molds, one has CA glue hardening in it now and the other has Tamiya liquid primer. I'll see how they go, otherwise I might look further at the casting route.
I am now fairly certain removing the badges with a knife will just result in the destruction of the badges, they really are tiny, and i don't have the steadiest hand in the world!
Once I have something to work with I'll post up some pictures.