engraving text on a model

[rodfrey]

Hi! This may have been answered but I don't even know the terms to search for. 

I would like to mill some letters in relief on some aluminum, for a woodburning brand. In this model

http://a360.co/2iWgg4z

I've got raised letters 1mm high.  The trouble is trying to mill around the tiny letters - my smallest cutter is 1mm, and it's far too big. (The letters are 4mm high.)

I do have a 20 degree engraving cutter that I use for text, but only when the text is ... "embossed"?  Anyhow, cut into the surface. Here I'd like to run the engraving cutter around the outside of the letters.  The majority of the field can be cleared with a regular endmill, and then once the letters are defined with the engraving cutters I can manually grind away any little islands.

Is there a way to do this? I've tried making offset contours, using the trace strategy, etc. but it feels like I'm just missing something obvious.

[zenkustumz]

one thing to think about is corners and curves of the letters. the tool.. (cutting bit) has to be small enough to make the corners and contours of the object. I would suggest first changing the corners and sharp edges to accommodate a round tool like a 1/16" end mill. Pretty sure you just select the inside or outside of the letters or surface and use 2D Adaptive clearing to remove the excess stock.

Hopefully this helps.. i'm not very knowledgeable but pretty sure i will have you on the right track.

John