Not all dyes were expensive. The purple dye was, but the rest could usually be derived from the flora/fauna around the immediate Roman Empire/Republic or even Italy.
There is practically no evidence for that. It could have been used by some units, but highly unlikely as widely as it is portrayed being used today. The shield insignias were most likely different for each legion.
EDIT: Why are you still labeled as "Junior Member"? I thought that went away after one's 20th post.
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