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Glad to see a fellow woodworker having success with Madcam. Was there anything else on your mantel project that Madcam was useful for?

Could you attach your 3dm file. and post. It does sound like you are doing things correctly. Are you using Rhino 3 or 4 ? Just need to know so I know which one to load the file in.
If I, we (forum...

On the madcam toolbar go to the second icon (regions) and select the box. It brings up the dialog screen in the screenshot. This is where you change the green box (material size). On the right side...

Heres how I do it.

1. create model
2. get the green box around it.
3. use that box for material size or add to top and or xy to your preference
4. use the rhino analyze tools (length,...

Cool!

You are right . A sphere should be recognized and it is in my version 3 . I don't understand "click new box". Pardon me for being to simplistic but here is the procedure.

Load Madcam by clicking...

If your Rhino file is set to inches the inch tool library comes up as the default.
Same with metric.
Dave

Two arcs or a circle, it should work. Attached is a cirlce with a profile toolpath. It is smooth both in looks and if it were cut it would be very smooth.
Compare to your result and see what you...

Are the settings you set to .0001 the Rhino mesh settings? If the mesh settings are to rough, curves will be jagged although not an xy square you discribe.

Set mesh to custom, minimum edge length...

Are you using any software to create 3d carvings to use on furniture?

Busted! No the nature of my work does not require carving . 98 % is 2d parts cut for veneer underlayment. cnc beats the heck...

Chris,
I fooled around with toolpathing your crown model and there is really nothing wrong with it. It is just a matter of milling those dental squares. The small size bit needed to get any detail...

I would put money on the latest Madcam build fixing your problem.
I imported your drawing into a fresh Rhino template and to small cutter error message is gone.

I forgot something. Did you download the latest release of Madcam? I do remember Joakim mentioning your problem in a previous version.
Dave

OK, this one is for higher authorities. Like I said, I don't get this error on my my setup but when selecting a small cutter in your file I get the same error message you got. I am at a loss.
Dave

When you do select a surface or solid and it is a box like object and you have shading on the green box madcam uses to show the surface or solid is selected does not show up very well. You may have...

I loaded your file as is and madcam would not recognize it. I then imported it into a blank .3dm file set up for inches. madcam recognized it and toolpathing did not freeze and worked as expected. ...

Hi,
I just ran a test with a .016 end mill in the Rhino 3 version and did not have this problem. Could you post a screenshot of your tool settings or better yet, the .3dm file. If your tool...

another try,
This is cut along curves making the assuption you would like a straight slot versus a curved slot .

What about this?

Z offset .5

Stepdown .0625

check multiple z cuts

Go to tools/toolbar layout and see if it looks like the attached screenshot.
Madcam2.0 should be in the top window and madcam 2.0 should be checked in the bottom window. Hope this helps.

I do a lot of what I call cookie cutter work (shapes nested on sheet material) and here is all you need to do it.

1. create a plane the size of the sheet stock I am using (example 96,48,0) This...

surface from 2,3,4 corner points or surface from edge curves might work.

I like the simulator. The best way to see is work with the demo and see what you think.

Ed,

You would be well served with some 2 or 2 1/2 d program . For 3d, Madcam can do it all for 3 axis machining. Like any cam program you need to establish your tooling and tool strategies and...

Hi Ed R,
I would like to put your language concerns to rest. You will have absolutely no problems in that regard. Comunication is exellent. The program is in english so no worries. As to pockets,...

Did a conversion that worked nice. Save eps. in Illustrator. Import eps. to Rhino. From Rhino you can save a dxf that will work nice for cam.

Here is a 54 page brochure on how to make money doing engraving. One example is exactly what you are doing.

http://www.rolanddga.com/pdf/engraving_for_profit.pdf

Below is a link to a turnkey engraving system, including software.

http://www.rolanddga.com/products/engravers/EGX-300/default.asp

Bordeaux is going in the right direction. High speed spindle is good, laser is bad for his material and application.

The above response by RandMan is dead on correct.