Damn, that did not help:/ Richard, please explain what you did in more details, pictures most welcome

Richard, we don't have any flex in any axis - so it can't be that, thx anywayz..

We 1st thought it might be caused by the double sided tape we were using, it had some flex in it, so we build a vacuum table that's 3 micron accurate. Then we cut a sample, still not right, then we figured it had to be the calibration of the machine, so we fixed that now, still not working, I'm really perplexed by this, it's going to give me restless nights!!!

Remember the corners are really small, it'll cut fine on big corners I think, it's cutting about 0.2mm into the corner but it's really noticeable on small corners,...

Is that bad corner at the start and/or stop point of the cut ?
just curious

IS this a stepper machine or a servo machine?

(;-) TP

Overload, it's all over, were ever the Cam program is using corner sharping it $#%$ up. Next step will be two use another program, maybe this machine don't like the one we are using..
It's a Servo mchine BR549

If your CAM is doing like Vectric's VCarving, then the problem might be that the actual angle of the V bit is not EXACTLY what is described in your CAM.
This has caused very similar problems numerous times over on the Vectric forum.
Just a possibility.
Russ

No, it can't be the program, we've been using it for over 10years on 4 other cnc machines and never experianced this problem. I'm pretty sure it's something messed up with the new machine...

Oh, sorry, I re-read that now, you refering to the V-bit cutter we are using, we will double check that first thing tomorrow morning, it'll be really weird if it's that cuz our cutter maker are really acurate and uses a shadowgrath to get it perfect. Here]s hoping it's that!

DOes it do this on EVERY small sharp corner?  IF so then LOOK to the servo tuning, too much overrun will do it every time. The servo will overun the position and then back up to correct.

Just a thought, (;-) TP