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Do you use a 3D printed holder for when punching?
I've found that when having to punch the same letter more than once, the end result gets rather messy.
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I haven't so far, but I think it would make it easier & neater too.
I have an old iron shoe horn as a base. With the hammer I go one light hit, then one heavy. So far so good.
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It might. I haven't seen much variation in the letter punches.
BIP39 words are no more that 8 letters so at most you'd be using 10 characters on a washer.