We just got a S40600 delivered and set up and are running into the same problem. Our equipment guy has set up several and told us to run the setup in PM for the S60600 and it works great. Today we tried to run the S40600 setup with some downloaded Oracal profiles and had some weird nesting/scaling stuff come out, not pretty at all. Switched back to the S60600 and all is well. SAi has the usual generic profiles on their site for for the S60600 and those seem to work fine. Still tinkering but interested to see if you discover anything. I will be getting in touch with flexi service to see what they say tomorrow.