I wanted to make a sign for my drone laboratory. I made it about as large as I could fit on my printer in a single piece, 220 mm wide. I sketched a rectangle in 123D Design and used the text tool to add the text. I made the base 3 mm thick and the letters 4.5 mm thick. I recessed the letters into the base 1.5 mm and used the subtract function to create recesses for the letters in the base. Then I printed the two parts in different colors.
The letters were a perfect snap fit in the base. They probably didn't even need any glue but I used some just in case. Only the "e" needed some slight clean up on the first layer to fit.
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