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Thank you very much. Im sorry for the late response. We ended up finding a way to do it by doing a polar array and a bunch of nodes. It took hours and was very tedious. Im sure there has to be a faster way.

 

Your attempt was close but off a bit. The letters need to have 90 degree edges as it will be cut out of foam on a cnc router and can only be cut straight down. So the face and the edge must be perpendicular. Secondly, when you extrude the letters straight out and then use intersect it messes with the letter spacing and overall width of the letters a bit. Clients have very specific brand outlines where they have fonts and spacing and aspect rations and stuff that must be followed 100 percent.