re: Name Board

Cool JJ... While my laser has a comfortable 6mm cutting capacity (can ramp it up to 9mm with multi-pass), I found the best solution for thick projects is to cut out using comfortable capacity (say 3mm) and laminate to desired thicknes..
I don't see any issues, especially when you're working on ply.
Cutting letters from one layer would provide a perfect flush fit.

Talking about long names, back in my computer days we had a Greek woman with a name similar (in length, maybe a few letters longer) that she insisted be fully used as her logon id...  I virtually had to reset her revoked access nearly on a daily basis until I refused to reset until she compromised on a 6 character userid.