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Hi
Small fonts are very tricky to get right and embroider well. To go that small most stock fonts just can't handle it so I just manually digitise the text. It also depends in the material or garment....if it's a jacket or badge material it is easier than say a thick fleece or knit polo.
It can come down to what looks bad on screen (uneven text) can embroider well but this for highly experienced digitisers. Finer needles and thread can help on small fonts too. If you are manually digitising the letters try and make sure the angle of stitching is going against the grain of the garment.
Rich
 

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If I need the text really small I even make the letters just by inserting manual stitch by stitch, not even using the column satin stitch. That way you can easily move the stitches to be exactly where you want them. If you need any help just let me know
Rich
 
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