Stencil problems

[Sabernathy]

I need help getting the white to cut out of this.
I'm trying to cut a stencil out of .040 styrene on a Colex Sharpcut. I have tried the double edge blade, 80 degree (didn't cut small letters well or thin lines) and I have tried a 3mm router bit (Small pieces got caught in the router and caused imperfect cut lines). Single edge blade just dances with the sharp turns. It might do a good job cutting but I don't have hours to wait for one test. Does anyone have any recommendations for completing this?
I have included the file I'm trying to cut.

 

[JBurton]

How big are you talking? I'd think a router would be the way to go, with this many narrow cut outs. Have you tried masking the opposite side to keep pieces from fly off as you cut? (Don't cut all the way through the mask) If your machine isn't level enough to not cut the mask, you could mask, then double stick it down to a piece of sacrificial material, then when you remove the double stick, it'll only be stuck as hard as the mask.

 

[Sabernathy]

How big are you talking? I'd think a router would be the way to go, with this many narrow cut outs. Have you tried masking the opposite side to keep pieces from fly off as you cut? (Don't cut all the way through the mask) If your machine isn't level enough to not cut the mask, you could mask, then double stick it down to a piece of sacrificial material, then when you remove the double stick, it'll only be stuck as hard as the mask.

It's a 20" circle. The router did a much better job accept for the points of the grass and the stars. I may try a combination of knife for grass and stars and router for other pieces after masking. I also have a double sided medium tack 18" adhesive roll that I'll attach to a sheet of MDF. My table isn't very level so I need to apply multiple sheets of mask too. Thank you for the help.

 

[VizualVoice]

The sounds like maybe an ideal laser situation

 

[John_Smith]

"Stencil" ???
For what? Painting, glass etching, sandblasting, ???
How many times do you expect to use it?

 

[Adam Vreeke]

just run it with the double edged knife with multiple passes.

 

[JBurton]

The router did a much better job accept for the points of the grass and the stars

If you have a V bit, I'd set my offset to 0 or no offset and run the V bit for those sections. If the blade doesn't work out that is.