How do I create a stacked text / layered text sign in VCarve Pro & Aspire with multiple depth levels and 3D clipart?

Overview

Stacked text (also called layered text) is one of the most popular sign styles in CNC woodworking. It uses multiple levels of cut depth to create a layered 3D effect where foreground text sits above background text, all carved from a single piece of material. The technique combines pocketing toolpaths at different depths with V-carve passes on each text layer.

The Concept

Imagine carving a sign where:

• The background is cut down 0.4" deep (the lowest level)
• Background text sits at 0.2" deep (the middle level)
• Foreground text sits at 0.0" (the original material surface, the highest level)

Each text layer appears to be a separate raised plane. V-carving is done on each layer separately with the start depth set to that layer's level, so the V-bit cuts from each layer's surface rather than from the material top.

Layer and Vector Organization

Organize design vectors on separate layers. This is essential for the template approach:

• Top Text layer: foreground text (stays at material surface)
• Bottom Text layer: background text (sits at the middle level)
• Background layer: the outer sign boundary
• Clipart layer (optional): any 3D relief elements

Weld the text on each layer into a single closed vector (select all text on a layer, then Weld). This gives a clean single outline for the pocket boundary.

Step-by-Step Toolpath Setup

Key Settings to Get Right

Pocketing clearance tool + second tool:

For large pockets, use a 1/4" end mill as the clearance tool (fast material removal) and a smaller end mill (for example 1/8") as the second tool for the corners and edges. Check the Pocket form's tool list to add both.

Start Depth on V-carve toolpaths:

This is the most critical setting. If the bottom text V-carve has Start Depth 0.0", the V-bit will try to cut from the top of the material and will run into already-cut areas. Always set Start Depth to match the floor of the pocket that text layer sits on.

Gap Above Model in Material Setup:

If adding 3D clipart that you want to sit proud above the material surface, set Gap Above Model equal to the clipart height in Material Setup.

Adding 3D Clipart to Stacked Text

1. Import your 3D component (V3M from the clipart library)
2. Position it where you want it in the design
3. In the Modeling tab, click Create Vector Boundary from Components. This draws a closed vector around the clipart footprint
4. Include this vector as an exclusion island in your pocket toolpaths (select it along with the text outlines)
5. The CNC skips that area during pocketing, leaving an uncut pedestal
6. Add separate 3D Rough and 3D Finish toolpaths constrained to that vector boundary
7. Recalculate all toolpaths. The 3D toolpaths now carve only the clipart area

Getting Clean Lines Between Levels

For the sharpest possible transition between levels:

• After the V-carve passes, do a second V-carve pass on the boundary vector between levels using a narrower V-bit
• This cleans up any fuzz or fiber left in the corners where the pocket meets the letters
• Or use a small tapered ball nose finish pass constrained to the transition zone

Common Mistakes

• Forgetting to set Start Depth on the bottom-level V-carve: the bit runs into already-cut areas and produces a mess
• Leaving a text group out of the Step 1 islands: the background pocket cuts that text down to 0.4" and the middle level is lost
• Not welding text on each layer into a single vector before using it as a pocket boundary: the pocket calculation gets confused by multiple overlapping open and closed vectors
• Adding 3D clipart after calculating toolpaths and not re-running pockets: the pocket machines through where the clipart should stand proud
• Setting the Gap Above Model too small for the clipart height: the model appears to sink into the material in the toolpath preview