I had a similar problem with CK Ali and it being too thin for my project--I was doing a large vinyl quote for a wall. My solution was to make it "bold" by creating a thin shadow layer using the outline feature in the Silhouette Program. The shadow was thin enough to still catch the shape of the letter, but thicker than the original. Then I just welded the "shadow" layer after deleting the original. It worked perfectly for me. Good luck finding a good font!