Hi davek, I like your approach to making them single pass. If you don't mind, I will include that information on the web page that I am building for the fonts.
I find that using the double cut, going both ways over each of the letters, gives me a bit cleaner looking finished letter. I do a lot of very small sized, 1/4 and less, and always look at the finished cut magnified to see how clean it is. I also use a very small "bull nose" end mill to do the engraving. Really makes it come out very clean and smooth on 6061 T6 aluminum that I am using.
It's kind of a double edged sword, needing to have the fonts be able to install themselves under windows as TrueType, and still having them appear to be a truly single line font. All the fonts are built using a 100% overlap in the font design, which tricks my TrueType font design program into thinking they are really looped TrueType fonts when they really don't have an inside and outside loop.
Thanks for the tip on making them truly single pass in CamBam. I like the idea of a script to do the extra work for you, that would really be neat. Maybe someone out there reading this will build one to use in CamBam.
I am using 9.8i and find it to be very stable, at least so far.
George