Material

We used 3/8" (1cm) thick plywood but you can use different thicknesses or use hardwood. You could even make these letters out of plastic sheet such as ABS or PVC.

Size

We made our letters about 3" (75mm) high, but you can select any size you like. Keep in mind that very small letters will be difficult to cut and the radiuses required may be too small for your cutting tools. If you want the letters to be able to stand upright, make sure that the material is thick enough.

Font

Complex fonts are going to be much harder to cut and sand. We chose a sans-serif font which made the project very straightforward. Also consider the minimum radiuses that your cutting tools can handle.