Powermill 5-Axis Toolpath Creation

I have a finished 3D prototype model that now needs a complete 5-axis machining strategy in Autodesk Powermill. Because the piece is larger than my machine’s travel, the model must be sliced into manageable sections first, then each slice programmed with a collision-free toolpath suitable for cutting the design in foam.

Here’s the workflow I have in mind:
• Split the solid model logically so joints are easy to re-assemble and any visible seams fall in low-visibility areas.
• Build roughing and finishing strategies for each slice, taking full advantage of 5-axis positioning to minimise tool overhang and avoid unnecessary air-cuts.
• Optimise feeds, speeds and step-downs specifically for rigid foam to ensure clean edges without over-machining.
• Supply the Powermill project, individual NC files, and a clear setup sheet showing orientation, fixturing points and tool list.

Acceptance criteria: every generated path must simulate in Powermill without collisions, stay inside the machine’s envelope, and preserve the original model’s dimensions when the parts are re-joined.

If you regularly deploy Powermill for complex multi-axis parts, this should be a straightforward assignment. I’m ready to send the model file and machine limits as soon as we agree on the approach.