All my cuts were kinda lopped off on the left side only, pictures might be easier to look at

Attached files

 

The foam is situated as looking over from the rear of the cutter basically like looking at the hood of a car while sitting behind the wheel.

X steps per 1032.091598 Velocity 40.002 Acceleration 20
Y steps per 19226.01028 Velocity 40.002 Acceleration 20
Z steps per 20000 Velocity 25.002 Acceleration 20

The cutter goes right back to zero without a problem so missing a step or stalling can't be the cause?

 

Maybe you should make it accelerate more quickly, by changing Y to 15 or less on acceleration. I think it's taking too long to get to position, while the X-axis is already done and starting to move to the next position.
Another possibility is that your cutter is a little too loose, and is tilting left / right as you cut. Are the u-bolt clamps tight enough?

 

Everything is tight, it is weird it only does it on the left side. I will play with is some more

 

I think I may have found my problem, the acme leadscrew dug it's way into the end plate i had installed causing ALOT of backlash. Going to a machine shop tomorrow to have them turn the end down so i can use a roller bearing to as a thrust washer

 

Ok, it was caused by the acme leadscrew end capture plate, I made a plate to hold a regular skate wheel bearing and adjusted the backlash with small washers until it was almost non existent.

Problem is now solved, whew!!!