Well @WillAdams, you may be right. So after work today, I tried the same toolpaths I had built before with various post processors (randomly) in VCarve: The built in Shapeoko (both inches and mm) ones, the generic GRBL one, and even the generic Gcode one. They all worked, including re-running the original toolpaths. So I think it was either one of two things:
EMI: Possible, but I still don’t feel this is very likely, as nothing else in my physical machine setup, workflow, or electrical service (as far as I can tell) changed. I can’t imagine that the VCarve produced G-code would react any differently to EMI than any other code. As far as brushes are concerned, I still have well under 50 hours of use on my Makita.
The other possibility: So when I first tried the VCarve code yesterday, my dust shoe got hung up on a clamp, due to the unexpected behavior of the code compared to the outputs from Fusion 360 or CC. This caused me to miss some steps before I shut it off with the E-stop. I fixed the issue, and re-homed and then re-zeroed and tried to run the same toolpath again. That was when I was getting the behaviors that would normally follow an EMI issue or a static shock to the machine (I’ve had those happen when I was first learning the basics). I wonder if it was possible that some “trash” got left in the controller board memory after my first issue? The main difference between today and yesterday is that last night I powered everything off completely, and the machine had time for any stored energy to dissipate.
Everything was fine today with any of the post processors. Ultimately, I got Vcarve to do some inlay work. First project is some coasters in cherry with a walnut inlay. Band logos for my daughter. I will continue to test, but I guess just chock this one up to gremlins in the machine for now. I do find VCarve to be slightly more user friendly than Fusion for text or engraving and it certainly does a tremendously better job of handling vectors. Trying to work with .SVGs in Fusion is a pain the butt and trying to do inlays that way proved to be impossible for me to figure out.
Thanks for the helpful suggestions all. Hopefully in a few weeks, I will have some finished projects to show. I’ve got a test inlay project glued up now so will see how it looks tomorrow.