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I know it's a bit late, but we use FlexiLetter and output to a small Graphtec plotter here where I work, and like Class Act said, you have to make sure all your type is converted to outlines instead of live.
Easiest way to do it in Illustrator is to use the Expand command in the Object menu.
As for the stroke, the easiest way to get *it* to outlines(cause Expand doesn't always work on strokes), use the command "Outline Stroke" in the Path submenu of the Object menu (Object-->Path-->Outline Stroke).
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