What are the things I should be aware of before filing? Can it be done online and what are the costs involved?

To take a step back, and for the benefit of anyone else reading this post, a trademark filing may seem very straight forward and simple until it's...

Is it a trademark infringement if a business name...

The use of a title to a single creative work like a song or album title is not afforded trademark protection. This is why we have 1001 songs titled...

What value do I really gain going from trade secrets, covered by NDAs, to patenting my methods and algorithms?

The only way to answer your question in a meaningful way would be to fully understand what we are talking about. In general, mere "methods" and...

How would I know for the name I'm thinking about for the brand is legally available for use and for the website ?

After you have done some general research on your own, for example, internet searches, basic search at the USPTO, etc. it is of course best...

You can be held accountable for trademark infringement anytime you present a false association, endorsement, sponsorship or other affiliation with...

Do I have anything to be concerned about should he attend? Is there anything he can theoretically do to undermine or stop us?

Well, yes of course there is. He can just sue you. Granted he would have the burden to show that you are infringing or defaming, etc. You state...

If I do not have an enforceable noncompete agreement am I violating any laws?

You have no issues unless your former employer can say that you exploited proprietary content, trade secrets, etc. from them and can show that you...

Am I allowed to use someone else's content on my website, if I credit the author?

As noted, linking content is perfectly acceptable. This is really no different from pointing to content located elsewhere. But placing another's...

If you are talking about just the design of the patches then that is a copyright issue. Any creative expression will be covered by copyright law...

How could I protect myself, my idea from being stolen when looking for funding or even when talking to a manufacturer?

You received some excellent responses, The best you can hope for really is to create an NDA/NNN agreement that will create a contractual...