I believe defining it as a T-slot cutter with corner radii will work.

I have a 34" diagonal extra wide curved for my main monitor, plus a 27" standard ratio (same height) next to it for reference documents, etc.. Seems to work fine for me.

I just did an undercut fillet with a T-slot cutter the other day. I used Flowline, with Direction and Depth Limits, and it worked perfectly.

Tool-edge feed rate would be useful in just about every toolpath, I think.

There's also less handling if you can get in-machine-inspection working right, reliably, and efficiently.

Whether or not inspecting on the same machine that made the part will meet your needs, will depend on your needs. If you want to do it properly, you should meet the same bar as for other measurement methods; get your machine laser / ballbar calibrated, do a measurement repeatability and uncertainty test, etc., and make sure that your uncertainty is less than 1/10 your tightest tolerance. You can include measuring a gauge block / pin / ring as part of your inspection process to warn you of any calibration drift, thermal expansion issue, or other problem.

The alternative is to reprobe frequently, up to every toolchange or even every cut if the tolerances require it.

Since the spindle is cantilevered out so far, if the front of the column gets warmer than the back, or asymmetric heating of certain other members takes palce, it will arch and lift the tool much more than the linear thermal expansion rate. This problem plagues the whole UMC line, in combination with poorly done thermal comp software. To fix it with thermal comp, they would have to add a bunch more thermocouples in several locations, and have a much more complicated compensation model. What I've heard works best on these machines is to turn off the thermal comp, and take every measure you can to keep the temperature of the machine constant within a very small window. For comparison, I get less than .001" Z change over 20°F on my CM-1's.

I've seen this problem on Fadal and Fanuc controls. Never seen it on Haas.

The old "wireframe" surfacing toolpaths have always given me very clean code when I needed it. Running modern machines I don't need it though.

Speaking of which, if patterns hold, we should be due for another brand new interface and version naming system again in a couple years. Any bets?

The rig I built to use for CADCAM at Conventus Orthopaedics in 2015 is still running strong as my 11 year old's gaming computer.

I think in order to help you, we need to know what you're doing. What exact cutters are you using, what holders, what machine, what cutting parameters?

Using an informative subject title will attract those more likely to be able to help with your situation.

Those parameters sound about right; you don't want SFM too high drilling in plastics, since they won't conduct the heat away. You could try pushing the feed a bit more perhaps, until surface finish starts to be an issue. I think tool life will be measured in total revolutions in the material, so a higher feed will give you more holes per drill.