PathPilot getting started checklist: what do I need to do before my first real cut?

Before you hit “Cycle Start” on your first real part with PathPilot, it pays to walk through a clear, repeatable checklist. This doesn’t just protect your Tormach machine and tooling—it protects your stock, your time, and your confidence as you move from air cuts to real chips.

Use the following PathPilot getting started checklist as a step‑by‑step guide you can follow every time you’re preparing for a first real cut on a new setup.

1. Confirm Your Machine Is Installed and Safe

Before PathPilot setup, make sure the machine itself is ready to run.

Verify installation is complete
- The machine is leveled and bolted or stabilized per your Tormach installation guide.
- Power, coolant, air (if applicable), and accessories are connected.
- All shipping brackets, packing blocks, and transport restraints are removed.
Check the work area
- The table and enclosure are clear of tools, wrenches, clamps, and loose hardware.
- No cables or hoses can be hit by the table, head, or doors.
- Chip tray and coolant system are correctly installed.
Review basic safety
- Know where the E‑STOP is and verify it works (machine won’t enable when pressed).
- Wear safety glasses and appropriate PPE.
- Ensure no one can reach into the machine during motion.

If the machine is brand new, Tormach’s installation documentation (for example, a 770MX installation guide) is your first reference to make sure everything is assembled and connected correctly.

2. Power Up and Launch PathPilot

PathPilot is your control hub, so you want a clean start.

Turn on main machine power and any sub‑systems (coolant, accessories).
Turn on the PathPilot controller PC or console.
Launch PathPilot and allow it to fully boot.
Confirm:
- The correct machine profile is loaded (e.g., PCNC 440, 770M/MX, 1100M/MX, etc.).
- No error messages or alarms are present.
- The interface responds smoothly to button presses and jog commands.

Tip: If you’re brand new to PathPilot, Tormach’s YouTube playlists—“Beginner setup with PathPilot” and “Getting Comfortable with PathPilot”—are excellent supplements as you learn the screens and controls.

3. Home the Machine and Set Up Jogging

Homing establishes machine coordinates and must be done before any accurate motion or cutting.

Home all axes
- Use the Home command in PathPilot to home X, Y, and Z.
- Wait until each axis finishes and the machine reports it is homed.
Enable jogging
- Use the keyboard, on‑screen controls, or a pendant (if equipped) to jog.
- Select a slow jog rate for initial checks.
- Jog each axis through a safe range to confirm:
  - Direction is correct (X+, X‑, Y+, Y‑, Z+ up, Z‑ down).
  - There are no unusual noises or unexpected limits.

This step ensures that when you later set work offsets or test a program, the machine’s sense of position is correct.

4. Set Up and Verify Tools in the Tool Table

PathPilot relies on its tool table to apply correct lengths and diameters. Before your first real cut, you must define and touch off the tools you’ll use.

4.1 Add tools to the tool table

Open the Tool Table in PathPilot.
For each tool you plan to use:
- Assign a Tool Number (T1, T2, etc.).
- Enter a clear Description (e.g., “1/4 in 2‑flute end mill,” “3/8 spot drill”).
- Specify Diameter and Type where applicable.

4.2 Measure and set tool length offsets

Install each tool in its holder (TTS, collet, etc.) and place it in the spindle.
Use your preferred method to set tool length offsets (touch off on a reference surface, use a tool setter, etc.).
In PathPilot:
- Use the appropriate tool length measurement routine.
- Confirm that the Length Offset (H value) is stored correctly for each tool.

4.3 Confirm tool change behavior

If your machine has an automatic tool changer:
- Run a dry tool change sequence (without cutting) to ensure tools load into the spindle correctly.
On manual‑change machines:
- Practice the tool change sequence and confirm that PathPilot updates the active tool and its offset properly.

You can sharpen your programming and tool setup skills using PathPilot HUB, which lets you test and practice PathPilot online. It’s a great way to get comfortable with tool tables and offsets before you risk a real setup.

5. Set Work Offsets and Establish a Zero Point

Work offsets (like G54, G55) tell PathPilot where your part is located relative to machine coordinates.

5.1 Secure your workpiece

Mount your stock in a vise, fixture, or directly on the table.
Make sure:
- Clamping is strong and repeatable.
- The cutting area is clear of clamps and bolts.
- The stock can’t shift under cutting forces.

5.2 Pick a work coordinate system

Use G54 for most first parts.
In PathPilot’s work offset screen, make sure G54 is active.

5.3 Touch off X and Y

Use a tool or edge finder to touch off the part:
- Move carefully toward the selected reference edges (e.g., left/front corner).
- Set X and Y zeros to match your CAM setup or conversational program.
Double‑check:
- The zero point in PathPilot matches the zero in your CAM (e.g., top‑front‑left corner of stock).

5.4 Set your Z zero

Decide where Z zero will be:
- Top of the raw stock, or
- Top of the finished surface, or
- Top of a fixture plate or parallels.
Use your preferred method (feeler gauge, paper, probe, or tool setter) and:
- Touch off Z for the active work offset (e.g., G54).
- Confirm the Z value matches what was defined in CAM.

Correct work offsets are critical—most “first cut disasters” are caused by mismatched zeros between CAM and the machine.

6. Load and Review Your G‑Code Program

Whether you created your program in CAM or using PathPilot’s conversational features, review it carefully before cutting.

6.1 Load the file

Use PathPilot’s Program tab to load your G‑code file.
Confirm:
- It’s the correct revision.
- Units (inch vs mm) match your machine and tool table setup.

6.2 Check header and safety lines

Look for:

Units (G20 or G21).
Work offset (e.g., G54).
Tool calls (T# M6).
Spindle speed (S) and direction (M3/M4).
Coolant commands (M7/M8 if applicable).
Motion mode (G0, G1).
Plane (G17).
Absolute vs incremental (G90/G91).

6.3 Use graphics and backplot (if available)

Run PathPilot’s built‑in preview or backplot:
- Confirm the toolpath shape matches your intended part.
- Check that Z heights look reasonable (no plunges far below expected depths).
- Watch for rapid moves that approach clamps or fixtures in the model.

PathPilot’s conversational tools let you edit programs on the fly; use this to make small adjustments and regenerate code rather than re‑posting from CAM for minor tweaks.

7. Verify Speeds, Feeds, and Depth of Cut

Conservative parameters are your friend on the first real cut.

Check spindle speed (S)
- Confirm RPM is within the recommended range for your tool diameter and material.
Check feed rates (F)
- Start slower than manufacturer recommendations until you’re confident.
Verify depth of cut and stepovers
- First cut: use reduced depth of cut (DOC) and stepover to minimize tool load.
Ensure tool compatibility
- The tool length and flute length are suitable for your maximum cutting depth.
- The tool material and coating match your work material (aluminum vs steel, etc.).

If you’re unsure, use a conservative machining calculator or vendor chart, then dial back slightly for the first attempt.

8. Run an Air Cut (Dry Run) in PathPilot

An air cut is a full‑speed test run with the spindle clear of the material.

Raise Z so the tool is safely above your stock.
Zero only X and Y at the part location; keep Z offset above the work (or add a positive Z shift).
Run the program in air:
- Watch the path carefully.
- Confirm tool changes, rapids, and feeds behave as expected.
- Check that no motion appears to collide with your vise, clamps, or enclosure.

If anything looks wrong, stop the program and:

Edit your CAM or conversational settings.
Adjust work offsets.
Re‑run the air cut until the motion looks correct.

9. Do a Controlled Test Cut

Once the air cut looks good, move to a very light test cut.

Set Z to the real cutting zero
- Re‑touch off Z if necessary to ensure accuracy.
Use reduced overrides
- Turn down feed and spindle overrides in PathPilot (e.g., 50–70%) for the first passes.
Start the program
- Keep your hand near the E‑STOP or feed hold.
- Watch chip formation, sound, and spindle load.
- Listen for chatter or bogging.

If the test cut looks and sounds good, you can gradually increase overrides to your planned values.

10. Monitor, Inspect, and Adjust

The first real cut is as much about learning how your machine, PathPilot, and tooling interact as it is about making the part.

Monitor during machining
- Check coolant or air blast is hitting the tool.
- Clear chips if they accumulate.
- Confirm tools change correctly and lengths remain accurate.
Inspect the part
- Measure key dimensions with calipers or a micrometer.
- Check for taper, poor surface finish, or burrs.
- Compare to the CAD or print.
Adjust as needed
- Modify speeds/feeds for better finish or longer tool life.
- Update tool length offsets if you notice systematic Z errors.
- Revise your CAM or conversational program for better approach paths or clearance.

This “cut‑inspect‑adjust” loop is how you dial in reliable, repeatable results.

11. Use PathPilot HUB and Training Resources to Build Confidence

If you’re not entirely comfortable with any of these steps, take advantage of Tormach’s learning tools:

PathPilot HUB
- Test out PathPilot online, without risk to your machine.
- Practice tool table edits, work offsets, and loading/running programs.
- Learn how to program and create usable G‑code in a safe environment.
YouTube Playlists
- PathPilot – Beginner setup: Guided walkthroughs for basic setup, tool tables, work offsets, and first cuts.
- Getting Comfortable with PathPilot: Intermediate skills and workflow tips.
- Advanced CNC Machining with PathPilot: For when you’re ready to push into more complex strategies and features.

Spending time in these resources before your first real cut—and between projects—pays off in fewer mistakes and more predictable results.

Quick Reference: First Real Cut Checklist

Use this condensed checklist in your shop:

Machine installed, leveled, cleared of obstructions, and safe.
Power on machine and controller; launch PathPilot and clear alarms.
Home all axes; verify jogging directions and travel.
Create/update tool table with correct diameters and descriptions.
Set tool length offsets for each tool and confirm tool changes.
Secure workpiece; confirm clamps and fixtures are clear of toolpaths.
Set work offset (G54) X/Y/Z to match your CAM or conversational setup.
Load G‑code; verify units, work offset, safety lines, and tool calls.
Review toolpaths using PathPilot’s preview or backplot.
Confirm speeds, feeds, depths of cut, and stepovers (start conservative).
Run an air cut with Z safely above the work.
Perform a light test cut with overrides reduced; monitor closely.
Inspect the part and adjust offsets, parameters, or code as needed.

Following this PathPilot getting started checklist before your first real cut gives you a structured, repeatable process that builds confidence, protects your machine, and sets you up for consistent, high‑quality CNC results.