The smoothing out of fonts, called anti-aliasing, makes them look better on screen. But anti-aliasing turns out to be a bad thing at very small font sizes.
Fonts in the 8 point and under range look better "aliased". But merely turning off anti-aliasing for a font doesn't do the trick. You actually need special fonts created for use at what I call "squint print" size.
A recent "Design View" newsletter article from Sitepoint, "Tiny Typefaces - Five Fine, Free Fonts," gives examples and more details. (You can subscribe and get their newsletters by email or just periodically check out their web site.)
Googlers may want to search for "free tiny font." For the squintiest of "squint print", try the diminutive 4pt "Tiny" font at a very punny site, "I Shot the Serif". Hmm ... I hope lawyers -- those purveyors of fine print -- don't read this blog.
Another choice, especially for display of code, is one of the Proggy fonts, designed by and for coders.
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