The use of 5-axis milling to produce a freeform component has become more popular than conventional die casting in many industries. Turbocharger compressor wheels are one of the components that require long a life-time and high durability. Improvements in 5-axis milling lead manufacturers to use this method to produce such wheels, because the cutting is more precise and there are fewer imperfections in the material. A ball end cutting tool is one of the commonest tools used to cut materials in 5-axis milling. This cutting tool leaves cusp marks on the surface across the feed direction. In this work, an optical inspection machine has been used to inspect the topography of the cusp surface. A model has been developed to simulate the marks generated by 5-axis milling using a ball end cutting tool. This model incorporates the cutter shape, number of cutting edges and the lead and tilt angles of the cutting tool, and it uses transformation matrixes to define the cutter position and cutting locus to simulate the cutting edge’s motion. By filtering the lowest surface of the cutting locus, it creates the surface that simulates the final surface. This result contained a continuous cutting mark that simulates a surface under perfect cutting conditions and with different cutting parameters. The difference between actual cutting trials and the simulation is less than 5.6%. Also, the feed interval marks within the pick interval cusps have been investigated using cylindrical form removal, wavelet filtering and polynomial filtering. Cylindrical form removal is a function in Alicona Infinite Focus Measurement G4. The wavelet filtering and polynomial filtering are provided by software called SurfStand. The results show that the arithmetical mean height (Sa) of a surface increased in proportion to the feed rate since the faster tool feed rate creates vibration during the cutting process, and if the spindle speed was too slow there was less cutting action.