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Michael writes

I have been using the laser cutter to cut words out for gifts. The font I used is Zapfino, with canals removed from the font to support the counters. That was done in Illustrator. Now, I’m using free font development software to make a proper font with that technique: Stencilano. Right now, I’m still working out the kinks. Feel free to download the current ALPHA version: Stencilano_0.2, below. Only lower-case and some kerning issues, and expect weird surprises.

Instructable here too…