Is there a calibration test that I can run?
You should be able to see it in the software.
I just googled and got a picture so forgive me if it isn’t quite right. The XY datum is what I am calling the model origin. It looks like you could possibly have an X offset for either the rough or finish pass.
Sorry Jenn, I’m all out of ideas then 
Will continue to follow to satiate my curiosity
Thanks Nick, I appreciate every ounce of effort you put in. 
JENN
Any chance the X axis hit one of the sides of the machine due to an obstruction or sawdust on the rails causing it to lose steps? I had this happen to me due to my poor cable management when I first set up the machine and the spindle cable got pinched between the left Y gantry and the linear bearing cap.
No, I generally watch and listen to my cnc religiously, anything out of the ordinary would have me at attention. It has been traversing quite smoothly.
JENN
Ok strike 1, I swing again… Your first toolpath shows a cutter with a 6mm diameter, is that correct? If it is and you’re using the touch probe for X Y Z homing, did you adjust the probe diameter in the settings to match?
Since you have the ridges on the bottom and left of the carve it seems the machine has an incorrect offset somehow.
How did you get a strike one? Well, My first cut is the rough tool path, and I zero x,y, and z. When the toolpath probe dimension pops up, I just click ok, since this value is correct based on the 6mm EM I am using for the rough cut.
If there is an offset somewhere, where should I start looking?
JENN
There is a probe diameter setting in the settings menu that should match whatever the diameter is of the tool you use when you probe X and Y, it doesn’t apply to Z.
If you’re using a 6mm endmill this should be set to 6mm, the default is 6.35mm
Hmmm, son of a gun. You serious? I’ve been using default values all this time. Well, nuttin’ left to do but… Let’er rip, One Mo’ Time.
Thanks, I will let you know how that goes, tomorrow of course
JENN
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Well I just looked at my my End Mill and it’s a .250", it translates to 6.35mm, so that’s why I have not made any change to the prompt and have left it at the default value.
See photo
6.35mm is correct for that endmill. In your toolpath setting above you have selected a 6mm diameter endmill so all the offsets will be incorrect. You should select a 1/4" endmill in Aspire.
all of the tool paths are calculated .175mm off because of this setting, Aspire “thinks” it has a smaller diameter tool. It still doesn’t make sense to me that the error is only showing up on the left and bottom sides of the carve.
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Should I change that value to 6.35 and try again?
Just noticed Jennifer that the bit description (if I’m reading it right) indicates that it has 3 flutes which would alter the speeds/feeds calculation also.
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You’re right, it is three flutes. Didn’t catch that. My goodness. My settings are a mess!
Thank you
JENN
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Have you reached out to Vetric for help? This is a head scratcher that they may have already encountered or, at least, could provide some troubleshooting input on.
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Have not yet… I’m compiling all the forum support possible in case it is something silly. So far two factors have been overlooked by yours truly, and I will address them and test. I hope to repost a better looking horsey, soon -
JENN
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Yes I would change the diameter to 6.35mm and also update the number of flutes as pointed out by Dave.
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Doing another test run now on a scaled down version of Mr. Ed.
Thank you guys!
JENN