I'm following your recommendations and re creating the whole project. It worth the effort to remove any possible variables. You responded to my PM but now it appears I can't read PM's so I'll ask you to copy your reply here too.
Your Recommendations:
1. fix the machine issues
2. clean up the vectors -in process
3. re-create the 3D components using a higher modeling resolution setting. Sometimes it helps to create the individual components in separate files at very high resolution, and then import them into the current project.Yup part of the rebuild of the models.
4. Adding a draft angle to components will help them machine better vs vertical walls.I now know how to increase the resolution and will save each component as it's own .3dclip and .crv3d and then create the new model these individual components.
This is what I don't know how to do