How does the Array Copy Toolpath work in VCarve Pro & Aspire for machining repeated parts in a grid?

Overview

Array Copy Toolpath duplicates one or more calculated toolpaths into a grid of copies. Rather than drawing duplicate vectors and calculating separate toolpaths for each one, you calculate the toolpath once on the original part, then use Array Copy to tile it across a sheet in rows and columns. This is the fastest workflow for batch production of identical parts. It is available in both VCarve Pro and Aspire. The form makes grids only, not copies along vectors.

How It Works

Array Copy Toolpath takes the source toolpaths you select and creates a grid of copies, spaced by the Offset or Gap setting you choose. The machine cuts each instance in sequence, stepping across the sheet. If you later edit the original toolpaths, the software updates the associated array of copies automatically.

The grid is always created to the right of and above the source toolpaths, so position your source part in the bottom left corner of the area you want the array to fill.

Workflow

1. Design one copy of the part with all vectors
2. Calculate the toolpath(s) for that one part
3. Open Array Copy Toolpath from the Toolpaths tab
4. Turn on the visibility checkbox (in the toolpath list below the form) for each toolpath you want in the array. The selected toolpaths appear in the Toolpaths list at the top of the form
5. Set Columns (X) and Rows (Y): the grid size, and so the total number of copies
6. Choose the spacing type, Offset or Gap, and enter the X and Y values (see below)
7. If the source toolpaths use different tools, decide whether to check Minimize tool changes
8. Click OK. The array toolpath is created

Spacing options:

• Offset: the X and Y values are the distance from the start point of one copy to the start point of the next. Add the part size to the gap you want. Example: a 6" wide part with a 0.25" gap = 6.25" X offset
• Gap: the X and Y values are the spacing between the bounding boxes of the copies. Example: enter 0.25" for a 0.25" gap regardless of part size

Minimize tool changes: only available when the source toolpaths use different tools. It groups toolpaths with the same tool geometry across the copies so they are cut together, giving the fewest tool changes. If unchecked, each copy is cut completely before moving to the next, with tool changes for each.

Key Advantage Over Drawing Multiple Copies

For a 4 x 3 grid of 12 name plates, Array Copy replaces 12 separate pocket toolpaths and 12 separate profile toolpaths with 2 Array Copy toolpaths (one for the pocket, one for the profile).

Working with Array Copy Toolpaths in the Toolpath List

Array Copy toolpaths are displayed as a parent item with the source toolpaths shown below it in a tree. Use the + and - controls to hide the source toolpaths. Visibility checkboxes are available for both the array toolpath and its sources. You can reorder the source toolpaths by dragging or with the up and down arrows at the top of the list.

Editing: To change the underlying design, edit the source vectors and recalculate the source toolpaths. The array updates. To change the grid size or spacing, reopen the Array Copy form.

Saving: Each source toolpath in the list represents all of its copies. If you switch off the visibility of a source toolpath before saving, none of its copies are saved, which lets you save just a subset of the toolpath types. In general, all included toolpaths are cut for one copy before moving to the next copy. The Minimize tool changes setting from when the array was created can change that sequence when more than one source toolpath uses the same tool.

When to Use vs Nest Parts

Array Copy is ideal for rectangular parts or parts where a regular grid layout makes sense (name plates, pendants, small signs). Nest Parts is better for organic shapes or when material optimization is the priority.

Array Copy vs Plate Production

Plate Production is a different tool: it designs and engraves multiple badges or nameplates using variables for text and positions imported from a text file list (for example badges from a customer database, or hotel room plates with consecutive numbers). Use Array Copy for identical parts and Plate Production when each plate has different data.