How does the Vector Validator work in VCarve Pro & Aspire: finding and fixing overlapping vectors, intersections, and zero-length spans?

The Vector Validator is one of the most important troubleshooting tools. It finds vector problems after file imports that silently stop toolpaths from calculating correctly.

What It Detects

• Overlapping contours: two vector outlines sharing the same space. V-carve and pocket toolpaths can fail with overlaps.
• Intersections: vectors crossing without being cleanly joined.
• Zero-length spans: spans with no distance between their nodes, which can cause calculation errors.

It does not report open vectors. Find those with Edit > Selection > Select All Open Vectors.

When to Use It

• After importing any DXF, SVG, EPS, AI or PDF file when toolpaths fail to calculate
• When a toolpath will not generate and there is no obvious reason
• When imported vectors look correct but carve incorrectly
• With script fonts or complex artwork before V-carving

How to Use It

1. Optional: select specific vectors. If nothing is selected, all visible vectors on the current side of the current sheet (on visible layers) are validated. The selection can be changed while the form is open, and the Search button's label shows whether all vectors or just the selection will be searched.
2. Open Vector Validator from the Drawing tab.
3. Click Search. Issues found are marked in the 2D view. While a search runs the button becomes Stop, and Stop or Close cancels it (issues found so far stay marked).
4. If zero-length spans are found, the Fix zero length Spans button is enabled. Clicking it removes them and clears their markers.
5. For overlaps and intersections, fix manually with Node Editing, Weld, Subtract or Interactive Vector Trim, then search again.

V-Carving Mode

Tick V-Carving Mode to have the Validator run its checks the way V-cutting needs them. It ignores intersections that exist within text, because those may come from problems in the font itself. If you still get intersections that involve text, try welding the text and running the Validator on the output.

Fixing Common Issues

Overlapping vectors:

• Use Weld Vectors to merge overlapping shapes.
• Delete the duplicate (Edit > Selection > Select All Duplicate Vectors finds exact copies).
• Use Interactive Vector Trim to remove the overlapping portion.

Intersections:

• Use Node Editing to split at the intersection and rejoin cleanly.
• Use Weld, Subtract or Overlap Vectors to resolve the geometry.

Zero-length spans: click the Fix button and they are removed automatically.

Pro Workflow

For any imported file: run the Vector Validator, fix zero-length spans automatically, fix overlaps and intersections manually, then retry the toolpath. This short process saves hours of confused troubleshooting.