i have the occasional piece where the end is chamfered 45 degrees across the entire width of the piece. when the outline is cut for these pieces, they pretty much always cut into the adjacent pieces on the points. is there any way to fix this without increasing the distance between ALL of the parts?
I would try changing the part outline so there is a very small (.004\") flat side where the chamfer currently meets the other side. i.e. make it a 4 sided part, instead of 3 sides.