I’m trying to mill letters that are the exact same width as my 1/32” endmill. I draw the letters as closed polylines in AutoCAD and import them in Carbide Create as a .dxf file. To achieve an efficient tool path, I want each pass to fully millout my letter (not take two passes at the same depth to mill out the stroke of an “i” for example). CC sometimes has problems (see dashed line in attached photo, it should be solid line) where there is a turn in the stroke of the letter. I drew this as 0.031” diameter with the inner radius at 1/2 the diameter. I’ve tried 0.03125”, 0.0313, 0.0312” diameter and all have the same issue (dashed line instead of solid line). Does anyone know why this is happening, or how to accomplish what I am after?
Note: It is important the lettering is exact as the pockets receive inlay.