Ed
Here is couple of things I have noticed. 90deg corners. original sign may have been cut with laser. This mean they payed big bucks for it!!!!!! Second, what I do is create 2 or 3 separate tool paths with same tool. 1st cut through alu facing 2nd cut foam 3rd if its alu backed. Only 2 if plastic backed. Each material different feeds and speeds. Key is is to use same tool so you do not see steps on the edges. 3m double sided tape will work. You may use studs or location pins for mounting letters( so they are in perfect line). In this case you have to cut is upside down and using upspiral will help you keep alu burr and drill location holes. Using same file take cheap piece of any material (templete) and drill stud or location pin in it and use it for install.
100% MADE IN TEXAS! It's not part of China partner.....