How about a couple extra mm's of letter height that you mill or sand off...

I like this idea.

Unfortunately, I think it would mean too much time for 1 part. We are looking to minimize our cost per print as I will be making around 100 duplicates.

I will post up a pic of the most current version when I get a chance.

I've tried printing stuff with recesses lettering with various degrees of success.  What works is printing with the lettering on top instead of the bottom, also play with the perimeter width setting, so you can get a small thin line.

In this case I have no option but to print the part with the lettering on the bottom.  I am aware of all the additional problems this creates with lettering but I cant print it any other way because of features on the backside.

I've tried printing stuff with recesses lettering with various degrees of success.  What works is printing with the lettering on top instead of the bottom, also play with the perimeter width setting, so you can get a small thin line.  Fonts:  the larger (bolder) the font the better. and don't make it overly deep.

Also when modelling the lettering, don't make it overly deep (1/2mm should be enough), and don't chamfer the edges, it muddles the sharpness of the lettering.

Something else you might try is lettering on a vertical wall, it actually works pretty well.

I am working on a small project the involves creating some recessed lettering.  I am familiar with the process of creating the lettering for the model but I can not seem to get consistent results when printing the lettering.  See picture (button shown is 1" across).

I have tried using KISSlicer and Slic3r to slice the parts with mixed results.  With KISSlicer certain letters work really well but others not so much. With Slic3r it's the same problem. The lettering will get filled with white paint so any flaws tend to show up easily.

Does anybody have tips for how best to do recessed lettering?

You could increase the number of top layers to include the recess so it was solid.  Or for a part that small just set your infill to 1 on every layer.

I get really good results with recessed lettering in the side wall of parts with a really thick wall.  That doesn't look to be possible here

I have tried using KISSlicer and Slic3r to slice the parts with mixed results.  With KISSlicer certain letters work really well but others not so much. With Slic3r it's the same problem. The lettering will get filled with white paint so any flaws tend to show up easily.

Does anybody have tips for how best to do recessed lettering?