Larken,
I'm doing all the design work in AutoCAD and generate toolpaths in MasterCAM. Letters are done with the standard MasterCAM "engraving" toolpath.
I'm using true type fonts, no single line fonts here.
The router motor is Kress FME 1050. I really like it!
I've recently made a compressor panel with very fine engraving that looks very cool. I can post a picture if you want.
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My CNC machine plans at www.8020CNC.com