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I need to replace a couple floor air return vents. One is in front of the concession stand and gets alot of foot traffic. It measures 20x30". I contacted my local HVAC guy and he said that one would cost $200. That seems excessive to me. I have been doing a search on the internet without success. Any ideas where I should look?

Sounds like this is a vent you stand on? In that case $200 is not bad for safty. I have several of these and they are made out of a heavy iron grate. Lucky for me they are across from the concession stand and I have a vending machine over them. Air still flows because the machine sits up almost 6 inches but no one walks on them here.

You could try to find HAVC supply houses. They often sell to the public if you want to install it yourself. Or maybe just look up steel suppliers and see if they have something like it.

Is it possible to do the grate out of another material that would be strong enough to stand on? Use 3/4" plywood and cut some slats in it. Would that work?

Try calling a steel fabricator company in your area. Take the vent to them and tell them you want two just like it. Many of these places will make an exact replica for less than it costs to purchase a new one.

Check these fine companies:

W.W. Grainger (branches all over the USA)

Johnstone Supply

McMaster-Carr

See if there is a company in your area that does rod-iron fencing.
Those guys can usually fabricate just about anything out of metal.

I had a local guy make me a special metal security gate.