I've continued to work on my Leg-o-Letters code. I now wanted to create "smooth" tiled letters where the top surface was completely flat and studless. This meant I would have to level the brick height to "fill in" the gaps up to a certain height. I was also aware that as I was using random placement of bricks and plates, the the stability of the resulting structure was quite unreliable. In an attempt to improve the stability I modified the code to create a base layer of generally lager plates, then to randomly fill on to the base plates, then level-up the letters to a given height, then add a layer of larger plates to create smooth, stud-less letters.
In the image above you can see the plate layer (top left), the fill of random bricks and plates (top right), the levelling pass to bring all the spaces to same height (lower left) and the tile pass to add larger tiles to create a studless top layer (lower right). As the placement of the bottom plate layer and top tile layer is random there is better change that the stability of each letter in the model will be improved.
