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How do make a tool path along each of the the boards so can remove them from the array without a milling operation after the boards are received?

Depending on your board outline, I'd recommend any of the following:

1. Use the Score Line option located in "Merge Wizard".  Scoring lines are 1/2 depth routed paths placed between jobs, so that each board may be easily snapped apart from the panel.  For more information, see the FAB 3000 Help Manual, Learn Guides | Merge Jobs | Merge Jobs Automatically.

Note: If you created a panel (menu: File | New | Panel...), and then inserted your jobs manually ( Tools | Insert Job...), you may have FAB 3000 determine the best layout for your score lines using the menu command: Tools | Add Score Lines...


2. Use the Add Cut Line option located in "Merge Wizard". Cut lines are board outlines placed onto the silkscreen layer used to help guide you in cutting out the individual boards from the panel.  For more information, see the FAB 3000 Help Manual, Learn Guides | Merge Jobs | Merge Jobs Automatically.

Note: If you created a panel (menu: File | New | Panel...), and then inserted your jobs manually ( Tools | Insert Job...), you may have FAB 3000 determine the best layout for your score lines using the menu command: Tools | Add Cut Lines (to Silk Layers)...


3. You can also create a dedicate Rout Layer with tabs to hold in the PCB.  Here's a releated link: 
http://forums.numericalinnovations.com/post?id=3277712&highlight=rout

Note: For best results, create the routs for each job (i.e. PCB), and then in your panel simple insert the jobs manually (or use "Merge Wizard").


4. Feel free to send your gerbers to us ( support@numericalinnovations.com ), and we'll be happy to create an online demonstration movie showing the different methods to use.  This is a free service, however please allow 1-2 business days to give us time to create the demo movie and upload it to our web server.

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