Ok - got some info back.
Semrock (located in Rochester, NY) may be able to help us. I just got off the phone with Colleen (585) 594-7055, and she told me all about their operation. They make custom dichros, notch filters, Rugate filters, you name it. They price everything by area, and they do offer volume discounts.
She said they have an off-the-shelf product that transmits from 660 nm to 825 nm, and reflects from 640 nm to 500 nm. They guarantee a minimum of 90% transmission efficiency at 660 nm, and 98% reflective efficiency at 640 nm. She also said that their specs were *very* conservative, and that we could probably expect 93% transmission and 99% reflective efficiency.
Now to cost: A lot of ten dichros that are 12 mm in size (doesn't matter if they are round or square) will cost $960 + shipping. So thats $96 each plus shipping. Not too bad, eh? To jump up to a 25 mm size (again, round or square) will cost $168 each plus shipping.
She said that it would take about a week to 10 days to process the order. She also said that if we ordered more than 10 units, the price would come down. As an example, an order of 100 of the 12 mm units would bring the cost down to around $60 per dichro.