I was able to use a trace op to get an outline, but when I set it to “clear” I get the same result as with the pocket operation. Will require more digging. KM doesn’t like something about the geometry, but I’m not sure what quite yet.
ok, when I set it to the 1/16" tool I get this, which is correct. so it’s the fact that KM is using the shaft diameter for the tip with clearing ops. and this makes sense. KM does not compute complex geometries for tool tips unless you use contour or lathe operations, which would be inappropriate in this case.
so a workaround is to create a flat endmill with the diameter you want to offset and use that to cut with your taper mill. if you choose tip width, you will get a chamfer on the letters. and that could be appealing.