Finished process that works for me.
By pocketing the cutouts, making the last cut (bottom) the rounding cut and adding a waste block on each side I was able to cut the pieces with just some uncut tiny left over 'tabs' and the double sided tape to retain the parts. Sanding the parts with a 1x42" belt sander just takes seconds to do each one. Mine is a Delta (now Black & Decker AKA Dewalt) and they cost around $100.NOTE: the 'tabs' only work because the tip is removed from the round-over bit so it does not cut all the way through.
. The tip will break-off after a few cuts anyway, forcing a change to the toolpath cutting depth.
There is enough clearance so the 'tabs' don't need to be sanded round, just sand at an angle top and bottom, after all, the thickness is only about 1/16".
The difference between the two files is the addition of two layers using pockets instead of a profile cutout.
Now to make the rest of the D7 cat (toy).........