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My LP cutter has been cutting things I've designed 1/4-1/16'' of an inch smaller than I have designed in Flexi. It may not seem like a big deal, but considering I'm cutting license numbers for airplanes, which have very strict rules, it becomes a big deal quickly. HELP PLEASE!|

I have checked the weed line, and there are no boxes checked. I also checked the knife offset, which is set to .030inches. I'm not sure what the blade offset does exactly. 

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Go to the resolution in Flexi and calibrate...  Cut a box,  say 3" long.  Measure it,  adjust the steps in resolution so that it is 3" long. May take a few tries. 

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