

I’ve dealt with this exact issue. Increasing font size (increasing smallest feature size) helps. As does printing the letters first, as you have found. Although sometimes the letters dislodge and become floating letters a la Alice in wonderland. Depends on your bed adhesion.
Then linewidth on the perimeter touching the letter is something you could look into. (Reducing linewidth to reduce overlap/bleed)
It won’t be one magic solution, rather a combination of several factors all contributing to a more acceptable result.
Who is this person?