How do I cut cycle time on a multi-tool job? Fewer tool changes, merged toolpaths and less wasted travel

Where the time goes

On repeat work the cutting itself is usually set by the material. The savings are in tool changes, travel between cuts, and extra depth passes. The software has a control for each.

1. Group work by tool

• The order of the Toolpath list is the order the machine cuts when toolpaths are saved to one file. Arrange it so all toolpaths for one bit sit together.
• Without a tool changer, save with Visible Toolpaths To Multiple Files and Group where possible. Consecutive toolpaths that use the same tool go into one file, named with the range it holds (for example Toolpaths_1-3). If same-tool toolpaths are not next to each other in the list, they are not grouped.
• With a tool changer, Visible Toolpaths To One File needs a post-processor configured for tool changes and a different tool number for each different cutter.

2. Merge toolpaths that share a tool

Merged Toolpath combines visible toolpaths that use the same tool (pocketing and profiling, for example) into one more efficient toolpath. It calculates several ordering strategies and keeps the quickest. Merge By Part finishes the features of each part together and respects the list order. Two limits:

• If the merged toolpaths have different feeds and speeds, the changes are written into the file, so confirm the post-processor supports that.
• Toolpaths on different sheets cannot be merged or grouped.

3. Arrays: minimize tool changes

In the Array Copy Toolpath, Minimize tool changes appears when the source toolpaths use different tools. It groups same-tool work across all copies. Left off, each copy is cut completely before the next, with tool changes for every copy.

4. Trim travel and passes

• On the Profile toolpath's Order tab, check more than one option and the software keeps whichever gives the shortest machining time.
• Use Start Point gives control over where the tool plunges, but the documentation warns it can lengthen the job because link moves get longer. Leave it off where the plunge mark does not matter.
• By default the software adjusts the step down by up to 15 percent either way if that reduces the number of passes. Maintain Exact Step Depth turns this off, so only use it where exact pass depths matter, such as laminated material.
• 3D tabs let the machine keep moving instead of stopping to lift at each tab.

Pro tips

• Merging and time-based ordering can work against holding small parts. Decide the hold-down order first (see the entry on cut order for nested sheets), then optimize what is left.
• Compare the estimated time before and after each change so you keep only the ones that help.
• Save the tuned set as a toolpath template so the gains carry to the next job.