Quote Originally Posted by Ger21 View Post
On my website, there are some modified macros that will zero the Z axis for all of the G54-G59 offsets at once, regardless of which one you are currently in.

As for material thickness, there's another option in the 2010 Screenset called "Material Offset". When checked, you zero the Z axis to the table, and Z zero is set at the material thickness value above the table. It's works basically the same as setting Z zero to the bottom of your material. If you are doing pockets, note that this will affect the pocket depth if the material thickness varies.
Thanks Gerry,
downloaded the macro's, seems like a better system to me.

I'll keep the ref method as it is at present and try other ways of sorting it out, the bed zero method looks useful but I can see ways it would land me in trouble sometimes ;)

I am fairly certain the issue is the variable thickness of the metal, surprised me how bad it is but it does explain why the part fails sometimes.