Why is it so hard for engineers to understand the concept of a nominal model? You call out a .01 edge break all around guess what when I break that edge and run it through Verification I have a collision. Call out a +.01/-.000 dimension on 600 holes and then model it to the smallest side of the tolerance and I machine it correctly to the middle to gain bonus on the Max material condition it is going to gouge. Guess what there are more drills out there than just the 118 drill point. Yes STI holes should be modeled to the correct nominal for an STI thread not the standard thread the STI is going to represent after it is assembled. Yes all STI threads require a 120 deg chamfer on the top of the threads. No I really didn't want to have to make up my own nominal model to get the Verification software to not freak out when I had the 3700 gouges in the because I programmed it correctly, but your model is not made for Manufacturability.

Just use a pocket toolpath and expand the outer chain that is around your part. Check your plane settings as well. I did a 1/8 cutter for the 1st toolpath and a remachining path with a 1/16 and it still didn't clean up. You need a smaller cutter like Ron suggested. Personally I would have the top of the part at Z0, then all my moves in Z are - moves and easier to see in the code.

My guess is that you need to eliminate the pspc value if you are using mpfan. I don't believe that post block has been defined. Alternatively you could add the pspc post block in by adding the following code: pspc # Creates spaces based tool level setting if sav_spc = one & omitseq$ = no$, " "

How can one get a legal version of Mastercam 9.1?