Like Iggy and Kevin, I tend to use a #5 blade to cut the outside shape. I cut the outside shape out first. (Well, if there are interior cuts, I drill those holes first, then cut the outside shape first and then the interior cuts with the #5 blade.) I then usually use a #3 blade to cut the letters out/apart. I have also learned if there is an inside cut that will be "accessed" when cutting letters apart, I don't mess with drilling holes there and cutting them out ahead of time. I do that cut as I cut the letters apart. This means only "fully enclosed" inside cuts like inside an "O" or a "P" or a "D" do I drill holes for and cut. That space in the middle between letters for example - I cut that out when I am cutting the letters. Saves drilling the holes and moving in and out on them. As far as putting them back together or waiting - I tend to either slide them back together as I cut them out - or set them together in order and then put together then I pull the pattern off each piece one at a time.