I recommend never using IGES it is a file format that is no longer maintained and has not been updated since the late 90's. STEP file format is my recommendation.

I suggest in FreeCAD you select your model and export it as a STEP file. I have never had an issue and use to use Freecad to extract parts from large die assemblies that would crash Mastercam or other software. I am not sure how knowledgeable your MasterCAM user is but importing a STEP file into mas...

Every day I use this similar code at the beginning of all tool calls G49 is standard practice and most production post processors will call it. No different from the G40 G90 or G80. The question is why after you call up a work coordinate (the G54) you are then telling the machine to rapid to Z15.0. ...

Can I ask why you don't just use multiple work coordinates. Use your main program for positioning and setting the work coordinate or even just shifting and resetting G54 to the new x0y0z0. I only ever have one program with no work coordinate specified. That way no matter how many I make it is all th...

Will get you in the ball park if you feel like removing the outer profile gcode created or give you an Idea of how to create the model you need to get the cut you want. I selected the green surface and did an adaptive path. I then selected outside which I circled in red in the image. That pretty mu...

If you divide the final pocket in two and add extensions, it can be done without manual editing: Well that is a nice trick :D gonna put that in my bag of tricks. I tried a profile with just the edges and didn't workout. I am not sure why sometimes just selecting edges works out and sometimes it doe...

Lots of variables left to the imagination. This is one possible way to do it with just a 1mm end mill. I would end up editing some of the code generated to make the process faster since the last pocket cut is mostly air cuts. Here is your file with 3 pockets.

Video showing the power of FreeCAD. I created this video for a new 6040 CNC user along with the macro.
Video link here https://youtu.be/DsRkUlEwouY
Code found in the forum here https://forum.freecadweb.org/viewtopic.php?f=15&t=68469

I am posting this here first and the video link in the tutorial section of the forum. Hope you enjoy the video and the macro that goes with it. I made it for a new FreeCAD and 6040 user. Before running the macro change your font location in the macro.. I commented out what a windows path might look ...

Created this video to help forum user who posted in the path forum. https://forum.freecadweb.org/viewtopic. ... 25#p591825

Link to the video is here https://youtu.be/FKzvTArttQs