So I played with all kinds of settings in PrusaSlicer. Nothing changed anything.
The only things that did improve the outcome some was:
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Forcing the letters to be printed first: then the letters are smooshed and bleed into the background instead of the other way round, which arguably looks better / more legible. Nothing to write home about though.
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Dropping the first layer's height to 0.1mm (the other layers are 0.2mm high): that improves the letters a bit.
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Dropping the first layer's height to 0.05mm: because the first layer is so thin, it becomes kind of translucent and the wider white letter beneath it sort of show through. The net result is that it drops a kind of gaussian blur onto the lettering, which actually improves them - especially at a distance.
Other than that, there's just nothing for it. And half of the suggestions I got concern other slicers, and I couldn't find them or equivalents in PrusaSlicer. Oh well...
I guess that's as good as it's gonna get.
I’m not sure if any of the tips will translate well to your project, but this is another project that worked with small lettering: https://youtu.be/e7K3BXWmipk
That being said, I printed this project, and the results were kinda ‘meh’ even after loads of manual cleanup. Probably one of the most tedious prints I’ve ever had to do.
So the guy printed throwaway first layer that he filed off to uncover nice- (or at least nicer-)printed letters underneath? Interesting concept. Too much time to spend on my little tabs though, since I make them by the bedloads for our many cables, but I like the idea.
Yeah, just building a single unit of these was mind numbing. If I had the money, I would’ve just bought premade buttons. I’ll never make one again.