I think I would like to try my hand at Robot Competitions but have not run across any in the Austin Tx area. Plus a little intimidated by the probable cost to build then repair/maintain
Nobody writes 41,000 line Gcode files by hand, right?, so whatever it was that wrote the code barfed it up.
It might be good to run the Gcode in a software previewer to see if it simulates as bad. If it doesn't simulate as bad, it might be an electrical noise spike or something confused the machine. You could do a second piece if you have the plastic to test it on. See if it goes crazy at the same spot.
I notice that the first one had a little notch in either side, right in the middle at the low point of the concave shape, and this one is straight in the same places.
Just a coincidence or part of the problem?