I am working on a typestyle right now that solves the problem of vinyl failure.
All vinyl eventually fails.
It fails really quick if you try to stick it to a frying pan.
I like Gacos Idea of putting a little round on all the corners.
I just did a signtific experiment.
I put a slight round on on a Helvetica A next to one without a round.
I stepped and repeated this and sent it to a plotter so I could see how differently they cut.
The one ones with the round made the plotter run "smooth" as opposed to the "un rounded"
Check it out you will see what I'm talking about.
I can see this making weeding a little easier also.