Big  Blue Saw


It sounds like it would work right? Cut out some letters and you end up with both a stencil and a positive of the sign. The only issue is that none of our machines are setup to cut a hole with the piercing action happening on the cut edge of that hole. They pierce the material inside of the waste area first (red dot) and then move out to the hole’s profile (red circle) to cut the edge of that hole. Which on a round hole usually looks something like this:

piercing cutting

The force of piercing the hole in general makes that hole a bit oblong and a little sloppy looking, so cutting it this way keeps the profile of the hole as clean as we can make it.