Initial plunge off path about mechanics HOT 3 OPEN

Hmmmm my first instinct is that this could be play in the router. Which type of z-axis are you using?

Another possible option is to add a lead in to your cuts which makes it so that the router bit doesn't raise and lower right along the edge of the part like this:

I am not familiar with Krabzcam, but I know CamBam supports it and they have a free trial version that might be worth playing with

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Thanks for your suggestions. We may have solved it by plunging the bit half way through the ply, withdrawing to safe height and then plunging to final depth. We have been using a 6mm twin flute cutter and maybe it is too stressed plunging the full depth in one go.

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