Thanks to all who made suggestions and offered advice. I am cutting foam now using the multiaxis > surface/solid > triangular mesh toolpath. Most of the 3D models I am tasked with cutting are triangular mesh models. Solids or surfaces would be better, but that's probably not going to happen. Here is what I did to make a all most ok toolpath 1) Built a solid column 1" in diameter capped with a 1" dia dome positioned in the core of the bust. 2) Created a rectangular confinement box around the bust in the xy plane 3) Using the constant cusp pattern, selected the solid column and dome cap as my machining surface 4) For tool axis control selected surface with lead/lag and side tilt as ortho to cut direction at each position 5) For collision control uncheck machining surface and select check surface. Select as the check surface the mesh model. 6) For collision control advanced parameters select and check the Extends tool to infinity box Bingo and I now have a toolpath with undercuts. Anti-Bingo 1) The toolpath is not normal to the mesh surface, its normal to the machining surface so some desired details are machined away 2) The stepdown value selected will be accurate for the machining surface and Not the mesh surface. So as the mesh surface angle changes the visible stepdown changes. A solution is to break the machining into smaller operations and change the stepdown values to compensate for the changes in surface angle. Question? If I use a lollipop cutter instead of a ballend mill and changing the toolpath stratigy can I get the undercuts normal? Bob

Thanks for the help, but I still can not upload. I can get to the X6 files and see 3 other files loaded there but when I drag my file to the page, no joy. Mozilla fire fox just wants to open it and not upload. I've tried also to use internet explorer and get the same results. I seem to be missing something critical Bob

I have tried constant Z and constant cusp with tool axis directed to a chain closest point. The chain is vertical passing along the center axis. I would post a file but do not know how to use the FTP site. Every toolpath I have tried fails to reach any under cut areas like the pedestal which is smaller in diameter than the top of the bust. I am using a 5 axis Thermwood router and want to believe X6 can cut this but so far no joy. Bob

I see no instructions and no hint. Why is this so cryptic?

Can some one tell me how to post to the FTP site? Bob

And what file would you like to see? The X6 file is to big. Bob

Good day I am trying to cut a triangular mesh model of a statute bust with the multiaxis surface/solid triangular mesh toolpath and not getting the desired results. No undercuts are tool pathed, and the results are looking like a 3 axis toolpath converted to a 5 axis toolpath. This is not good. I've stumped the dealer and hope some one here can help. I've tried both X5 and X6 with the same disappointing results. Any help would be appreciated Bob

Try splitting the STL using Rhino 4.0. There is a free evaluation down load available for use with 24 saves allowed, until you decide to purchase. This is a great program for prepping files for importation into Mastercam.

Phil You could also use Rhino to open and manipulate,mangle, or edit that STL file. Its very fast and STL friendly Bob