If I am reading this right, that helps to clean up the side walls of the letters. That isnt the problem so much, it is the gap between the letters that a small amount of material is being left I assume due to the clearance tool being too big to get in as well as the V-bit. I am assuming you need to put a smaller end mill into that area and clear it out which definately would work but I dont want to triple the clearance time which has been the only way so far I have found to clear it out.
Am I missing somehing. I attached the Aspire file above but had to ZIP it due to the size. You can preview the toolpaths and zoom in and see the material left between the letters in some places. I can sand it out but would rather fix it and learn how to prevent it for long term benefit.
Thanks for the information you attached. That was certainly interesting.