Thanks, for the additional info I was forgetting Josh C. That was exactly what fixed the issue. Now on to post fixing to output the correct codes for our formboring takisawa.

Operation Defaults, Template Files, and Operation Libraries ready for import is all I can suggest.

https://whatsnew.mastercam.com/2018/en-us/Content/Design_Enhancements/Wireframe_Enhancements/Modify_at_Intersection.htm

You just need to get one of these But seriously, all mentioned above help greatly...just the experience factor just takes some time to develop :side note: I tend to stock with only a few standard stock sizes to minimize prep and for stock availability...the smallest piece of stock that if fits, that works for the process, that's what the part comes out of...sometimes you do remove a little more stock than you might but by having a prepper block ready to go....you can have it on the machine pretty quick...plus I have the luxury of programming off the floor...no machine sits and waits for me..

Back in the dim dark days of Okuma, before tool setters on the machine, this method was the standard practice. This was well before the days of PC's and Mid Auto Manual as well (I'm talking the OSP2200 control and paper tape days). But nowadays, there is definitely no need for that, especially on a control as powerful as the P300.

I agree. I was spending as much time documenting things for the setup sheets and tool lists as I was programming. Then, if I had to make a change, I would have to go back and fix my documentation. My current setup sheets are basically a one click and done, with the exception of Viewsheet screen shots for WCS setup, chuck jaw, etc. detail. A lot of times I will setup my laptop at the machine and work with the operator and see how I can make his job easier, safer, and more efficient. I feel the same way about making my post processors generate code that requires no hand edits. I recently developed a post that outputs block numbers that match the operation numbers, so a machinist can look my setup sheet, find which operation they want to run or re-run and then search for that block number. I worked as a machinist many years ago where the programmer's nickname was: "I think I got it right this time, Bob" - Not so much fun - Did you ever look at the Active Report templates that I posted back on February 23rd? (Funky text colors in the link below, click on the "Free Active Reports Setup Sheet") I like looking at how other people do things and try to learn from everything I see.

You could use 5 axis curve toolpath, just have 4 axis output in the parameters page. We do it all the time to run chamfers along outer edge on a 4 axis mill.

sometimes trimming in 2D helps , they don't have to intersect in all 3 axis

This info came from the Mastercam Forum, I added pictures to make it easier for my students HLE Hardware acceration.pdf

After thinking about this a little more, it sounds like the AE is not familiar with the use of the Mid-auto manual function. Where this comes into play is touching off for a zero offset. When you call a tool in MDI, the tool offset is active, but if you put the machine into manual/handle, it cancels the offset. Then if you try to touch of a part and CAL the Z, the tool offset is not accounted for. Instead, after calling the the tool you want to use to touch off with in MDI, turn on Mid-Auto Manual, leaving the control in MDI. You can handle the tool into position and CAL Z with the tool offset being accounted for.

Old School Surface Rough Pocket does a good job with this if you willing to put in the effort. I have used the OPTI-Rough and it does okay with these tools, but you cannot define the tool with custom geometry or life will become unbearable very soon if the file is more than a block with 4 holes in it. Defining them as Mastercam Bull endmills using the OEM defined Tool Radius is the only way to use OPTI-Rough with high feed cutters in Mastercam with any file that going to be complex. Problem with old school surface rough pocket is stock awareness as far as I know is still not part of the toolpath, but if the shape is a standard shape then surface rough pocket is a good choice for these types of tools. Odd Shape, Forging or Casting then OPTI-Rough is my go to toolpath with these tools and then adjust my parameters like I want.

Part.mcam with axis sub curve and swarf would work well too. Idk what you have available.

I made a quick little video. Hope this helps.

Organization within your file is very important going forward, your example is a perfect case to show why every level should be clearly labeled.