I'm speaking about "Generating" the "toolpath", not the gcode that comes from it or the actual cut at the machine. The program that he is using tops out at around 100 MB... (Trying to bring in a 100 mb + STL usually doesnt work, let alone, toolpath it..)

Yes, the software he is using has a "fit arcs" selection, which will turn a 30,000 lines of code file into a 6,000 line file, but again, this is not really the area I was refering to...