The software is all set up for metric, and I've been using it in metric for the last few weeks with much larger files using equidistant offset and plunge roughing etc, it's just when I'm doing profiling the issue turns up.
To replicate the issue, just do a grid of 9 circles, tell it to profile mill to the inside (or outside) of them, put 18-20 steps for it to mill down on all 9, compute the toolpath, then post and it'll crash (probably).
I've tried it setting the whole thing up on inches too, and it still crashes it, so I don't think being metric is the issue.
It seems that this issue is repeatable so far, so re-doing the part results in the exact same issue... I've upgraded graphics drivers & tried turning off hardware acceleration as BC support suggested, which had no effect.
The post processor came with bobcad, but I don't think this is the issue either, as whatever post processor I try I get the same result.
Thanks for your help Allen, let me know if you have any more ideas