small lettering digitizer

If you haven't found something already, Embroidery Fonts Plus is free and works pretty well with all kinds of lettering. You can download it from embroiderydesigns.com

Yes Alrich,
I'd love to find a few great fonts also.
Small lettering on fine fabric -- very difficult to get a good sew out.

nobody can find a source with small predigitized fonts, that can be universal for everybody.
Guess why?
All who searching something like that, better try to search for professional digitizers for specific help.
And yes, it costs money, cause its extremly professional job.
Thats why guys, digitizing job (professional's) cant be on a base of stitch count..
:)
someone interested, welcome ask me for their specific needs.

With practice you can develop you small lettering skills.

First most programs come with specific fonts that have been digitized for small lettering, If you can use them. If not you will need to do some editing.

You need to only use the minimal underlay in the center, run the smallest stitch compatible with your setup and only one or two lines, then your satin stitch should run with a low density setting, this setting will vary you will have to test it on the material you use. You will also get better results using a topping/solvy to add structure for the lettering and you will get better results using a cutaway backing in the 2 - 3 oz range. Small lettering is a challenge but is not all that difficult to master if you work at it, just takes patience and clear thinking. You can only put so much thread in a small area, use this statement as you thinking baseline and I know you will like your results. ;)