Die Cutting 3003 Aluminum

I think shearing/punching will create a burr. Plasma also. Laser and water jet cutting might not, but ask around first.

How many pieces? I don't know if die cutting will satisfy your needs, but if you need only a few dozen, then die cutting is cost prohibitive.

WaterJet will be the most likely candidate. You will have a sharp edge, but technically, it should not produce a burr.

Laser can leave a burr in the form of dross -- however a really good operator should be able to keep that to a near undetectable level.

You haven't told us how many, or your budget.

Chemical milling is the way to go. I used to manage engineering for a wet process equipment manufacturer. Put a big sheet in one end, get perfect parts out the other. Our small card wet process equipment could transport credit cards through 50 feet of process chambers.

You can stamp and tumble in a vibrating tray with stone medium. That would de-bur them.

There are a number of ways to do it.

Any good sheet metal house with a turret punch press could punch any amount you want. Set up time should be about 30 minutes. The parts should be burr free but would still be sharp. I could build and run a die for you but you need alot of parts to justify the cost.