Just dawned on me that in a few weeks I'm getting a used computer-assisted cutter which is currently equipped with a router appliance and which can also accept a laser cutter. I wonder if a laser could cut the individual letters (from wide masking tape). Can't imagine why not.
As for de-masking, all the paint I've used gives you a time when it is safe to remove masking tape and not risk edge bleed. Most catalyzed urethane I've used lately is 4 hour mask time, but on a breezy day with low humidity, you can lower that to 3 hours.
