For machining of the sculptured surface, traditional methods of choosing tool orientation and cutter geometry for multi-axis surface milling mainly depend on the expertise and experience of manufacturing engineers. If a preliminary analysis system is available to evaluate appropriate tool orientation and cutter size before the manufacturing process begins, the errors caused by lack of experience can be avoided and the lead time can be shortened. In this paper, a method that uses surface point data and visibility cone theory is proposed to analyze the feasibility of cutter diameter. The geometric analysis is based on the properties of the surface and the geometry of the cutter. Three types of cutters are considered, i.e. ball mill, flat end mill and round end mill cutters. The developed manufacturability evaluation system enables to analyse and suggest feasible tool orientation and constrained cutter geometry for the process planning of multi-axis surface milling. Finally, an example is given to demonstrate the capability of the developed evaluation system.