Why are my stars in the upper right corner different from the rest?
See:
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Is the material really flat and held down well? Depth variances could lead to the ones in the lower left being more rounded I would think.
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Agreed, if the are indeed the same size in the program, then it has to to do with the material or something affecting the ability to cut the same depth.
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The stock is flat and the same thickness. I am going to resurface my waste board, once I find instructions from start to finish. Maybe this will help.
Stars are the same size in the program?
Collet tight? Maybe the bit slipped if those were cut last.
Stars are the same size. Everything was tight.
Relative to itself, or to the XY plane of the machine? Touch off your tool in the 4 corners of the union, and note the Z height.
Surface the top of the stock to the lowest point measured. 
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