I am currently carving a headboard that when completed will measure 60" wide by 27" high. My initial plan was 72" wide by ~30" high.
I'm carving it in three sections of 60" X 9", using 2 X 10 select pine.
the reason I had to reduce the size is because when I tried to save the 72" X 9" pattern to the card, I would get the "card full" error.
The pattern is .800 deep.
I only needed a couple of MBytes more to fit it on the card.
On a positive note, I have done two sections so far and I was happy that the machine was able to carve exactly as drawn, so that the carving matched perfectly when the sections are aligned together.
I'm using the latest version of the software. Long ago when I tried to carve a 48" diameter Mayan calendar, It was ruined because the carving came out different lenght on different sections. The measuring routines in the machine have improved quite a lot since then.