1. Fillet the internal corners to the kerf width of whatever method you're thinking of using to cut out the logo, which will probably lead you to
    2. Try it with the interior features of the logo deleted, so you just have one big shield shaped cut out.
  • I was thinking of water jet cutting the interior, but yes there is a certain amount of "look at what I've designed and damn the actual construction" in this model.

  • I was thinking of water jet cutting

    On a good day, you're looking at 1mm kerf width unless you find somebody with a micro nozzle. That rounds off the internal corners something like this on a shield 28mm high, if your cutout is smaller than that the effect is obviously greater.

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