Hi Tom, yeah it's pretty much the exact same thing on the profile on your cutting object:
If you tune up that curve so it's fully smooth with the lower line, and then make a new cutting block out of that, I'd think that should fully clean things up. A quick way to put in a smooth curve between 2 lines is to select the lines and then run Construct > Blend.
At some point I may modify the Edit > Join command to look for things that are nearly tangent and automatically adjust them to be fully smooth with one another but it's a bit of a delicate thing to do always because in some cases it can kind of change the shape too.
- Michael
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