How to smooth out entry and exit of tool path "nibs"?

[WillAdams (William Adams (Carbide 3D))]

The best way to avoid this is to avoid slotting and add geometry so as to provide a roughing clearance, and cut as a pocket down to at least tab depth — then the finishing pass can plunge along the finished edge and not deflect.

Adding geometry to cut as a pocket with a finishing pass

One technique which is often suggested to avoid slotting is to add geometry around a part which one wishes to cut out and cut as a pocket down to tab depth — here’s one technique for that. In this case, the project is a bevel gauge which will be cut out of 0.0625" (~1.5mm) thick aluminum: [bevelgauge] Due to the narrowness of the angles, an 0.03125" endmill has to be used, so after importing and scaling the file (we will be cutting out one which is 3") we select the perimeter and offset it tw…