This is a problem because the minimum that I can get away with spending is $1500 on custom holograms.
Do you mean maximum? This is what I thought I understood...
* Must be unique and very hard for someone else to replicate
This, by its nature, is the opposite of cheap. It's sort of the same reason mining is hard - if it were easy, it wouldn't be useful.
Here is another thing you could consider for holograms. Find someone else who is interested in custom holograms, and go in halfs. Use their per-piece laser numbering option to mark PrintCoins.com on them, and keep the hologram very generic Bitcoin so the unmarked ones are valuable to others. Maybe I might do it, but I am not yet sure just how I would use another hologram set.
Who knows, others might want Bitcoin holograms for completely unrelated purposes, like with MtGox or MemoryDealers or IBB or whoever lasered on their name. Ask Roger over at MemoryDealers if he'd like a bitcoin logo hologram with lasered "ask us about Bitcoin" that he could stick on all his outgoing invoices and shipments.
If you sold Bitcoin holograms, I'd probably buy a few sheets no matter what they were.
So example, order 15,000 holograms.
10,000 of them say "PrintCoins.com"
1,000 of them say "Ask me about Bitcoin"
1,000 of them you just leave blank
3,000 of them say things your "sponsors" want on their own holograms
If you are worried about selling 1500-3000 bills.... I have already sold 1500 coins in like my first or second month, and have sold well over 3000 coins after having them out a total of not even three months.