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Onion Skin Help? Tool Deflection? or Parts moving?

 We are having issues with onion skinning leaving a lip on the bottom edge. But only on one side of this part.(See Pics)  It doesn't look like the part moved because the lip is on the side where the lead in-out is on. We are currently doing some tests,   Is the clean cut where the router has a full load ,or on sides next to other parts where it only gets to cut half of the material?

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