A typeface that looks crisp on screen can be physically impossible to cut. The cutter has a radius; the letter has to accept it.
Three constraints that decide the typeface
- Minimum stroke width must exceed the cutter diameter, ideally by 1.5×.
- Counters in a, e, o must clear the tool or they close up into blobs.
- Sharp interior corners become radii — pick a face where that reads as intentional.
Cutter selection by letter height
| Letter height | Cutter | Min. stroke | Strategy |
|---|---|---|---|
| 25–50 mm | 1.5 mm 2F | 2.5 mm | Profile + tab |
| 50–150 mm | 3.175 mm 2F | 5 mm | Pocket + profile |
| 150–400 mm | 6 mm 2F | 9 mm | Adaptive pocket |
| Any (incised) | 60° V-bit | n/a | V-carve |
Frequently asked
Best material for exterior signage?
Marine-grade HDPE or powder-coated aluminium. Both hold edges and survive UV without refinishing.
