Rounding sharp corners and minimum path size

Question

I'm in sign business. We use illustrator to prepare files to cut vinyl stickers (foil) on a cutting plotter.
I suspect there is dedicated sign software that handles the problem below, but i'm stuck with illustrator to do this.
There are 2 requirements for cutting vinyl:
1. Corners can not be too sharp, or they will easily come loose.
A combination of positive and negative offset effects with "round" selected, stacked on top of eachother, does the job.
The negative offset does remove some parts however.
2. Minimum area: lines can't bee to small. En general rule of thumb is no to go below 1mm.
A function would be desired that, let's say, removes parts that are extremely small (for example 1 squared mm). Other small parts should be made somewhat thicker.
So instead manually checking and preparing every file, i want illustrator to do this for me!
Using effects, actions, scripts, plugins, whatever.
See the following image:
https://dl.dropboxusercontent.com/u/8911045/example.png
(the insert image button doesn't seem to work with me at this moment, i'll try again later)

Answer 1

No special filter that does all the magic, unfortunately
It's not that you have to draw every path point-by-point. You can use commands like outline stroke, boolean operations, etc., etc. and get paths not fully optimized, but clean enough for vinyl cutting.
And it's not that related portions of what you need to do frequently cannot be scripted. It's that scripts are very literal; very explicit. If you expect any kind of one-size-fits-all solution, you have to very specifically nail down the requirements that would work for all situations.
You would be better off just carefully thinking through the steps that you find yourself doing repeatedly, and then consider the portions of them that can be at least semi-automated by recording a macro (so-called "Actions" in Illustrator).
Most of the functions you need to automate are commands in the standard interface. That's the domain of macros, not scripts. And macros are much simpler to tweak on-the-fly than scripts.
For example, although I can and do write my own scripts, I frequently use an Action to create "halos" around individual parts in exploded assembly illustrations that are imported DXFs. It basically :
Runs the Simplify command
Sets stroke attributes
Outlines strokes
Unions the resulting fills
Names the selection
Duplicates
Releases compound path
Unions
Offsets path
Changes fill to white
Sends to back
Groups
That yields a single offset path around the drawing of the part which creates the "halo" that visually separates it from other parts in the assembly order which it partially overlaps. (Think of a stack of washers, nuts, grommets, seals, etc. closely spaced along a single thrust line.)
That macro is run with a single click dozens of times in the course of processing a single drawing. The first step (Simplify) often needs different settings for DXFs from different sources. It's a simple thing to do a couple of tests and tweak the parameters of that one step in a given session.
Scripts may feel more "exotic" but in Illustrator scripting is more for things that the standard interface can't do. (One should be able to invoke a macro with a script and vice-versa, and that, like everything else that falls into the Adobe feature request black hole, has been requested since AI first acquired scripting.)
JET