Comment Re:That, or... (Score 1) 258
You wouldn't cut a complex surface with a normal end-mill, you'd use a ball end-mill as you say. You'll always have some amount of scallops in that case, you control how large they are by using a fine step-over, and if that's not good enough you'd have an after machining finishing operation to minimise the scallops. Millions of injection moulding tools and dies are made this way.
Granted multi-axis machining can be better with a ball end mill, but in that case you'd be using a 5 axis machine where the cutter is angled with lead and lag from the surface normal.
4 axis lets you do continuous machining around a cylinder
For 'prismatic solids' multi axis (4 or 5) just saves you some set up time, e.g. machining on the front face, then top face, then back face, but it's still a 3-axis (if you include helical or ramped entry) machining operation. This would be an indexed table, it can be positioned between cuts but it can't run simultaneously with the cutting path