diff --git a/src/Mod/CAM/Path/Main/Sanity/HTMLTemplate.py b/src/Mod/CAM/Path/Main/Sanity/HTMLTemplate.py
index bfddab0009..585d15d5c9 100644
--- a/src/Mod/CAM/Path/Main/Sanity/HTMLTemplate.py
+++ b/src/Mod/CAM/Path/Main/Sanity/HTMLTemplate.py
@@ -1,6 +1,7 @@
 # -*- coding: utf-8 -*-
 # ***************************************************************************
 # *   Copyright (c) 2024 Ondsel <development@ondsel.com>                    *
+# *   Copyright (c) 2025 Billy Huddleston <billy@ivdc.com>                  *
 # *                                                                         *
 # *   This program is free software; you can redistribute it and/or modify  *
 # *   it under the terms of the GNU Lesser General Public License (LGPL)    *
@@ -33,304 +34,627 @@ html_template = Template(
     <meta http-equiv="content-type" content="text/html; charset=utf-8"/>
     <title>Setup Report for FreeCAD Job: Path Special</title>
     <style type="text/css">
+        /* Reset margins and padding */
+        div, dl, dt, dd, ul, ol, li, h1, h2, h3, #toctitle, .sidebarblock>.content>.title, h4, h5, h6, pre, form, p, blockquote, th, td {
+            margin: 0;
+            padding: 0;
+        }
+
+        /* Responsive image handling */
+        img, object, embed {
+            max-width: 100%;
+            height: auto;
+        }
+
+        /* Base styling */
         body {
-            background-color: #FFFFFF;
-            color: #000000;
-            font-family: "Open Sans, DejaVu Sans, sans-serif";
+            background: #fff;
+            color: rgba(0,0,0,.8);
+            padding: 0;
+            margin: 0;
+            font-family: "Noto Serif", "DejaVu Serif", serif;
+            line-height: 1;
+            position: relative;
+            cursor: auto;
+            word-wrap: anywhere;
+            -moz-osx-font-smoothing: grayscale;
+            -webkit-font-smoothing: antialiased;
+            max-width: 62.5em;
+            margin-left: auto;
+            margin-right: auto;
+            padding: 20px;
         }
-        h2.western, .ToC {
-            font-size: 20pt;
+
+        /* Container styling */
+        .center-container {
+            max-width: 62.5em;
+            margin-left: auto;
+            margin-right: auto;
+            padding: 20px;
+        }
+
+        /* Headings */
+        h1, h2, h3, #toctitle, h4, h5, h6 {
+            font-family: "Open Sans", "DejaVu Sans", sans-serif;
+            font-weight: 300;
+            font-style: normal;
             color: #ba3925;
-            margin-bottom: 0.5cm;
+            text-rendering: optimizeLegibility;
+            margin-top: 1em;
+            margin-bottom: .5em;
+            line-height: 1.0125em;
         }
-        a.customLink {
+
+        h1 {
+            font-size: 2.125em;
+        }
+
+        h2 {
+            font-size: 1.6875em;
+        }
+
+        h3 {
+            font-size: 1.375em;
+        }
+
+        h4, h5 {
+            font-size: 1.125em;
+        }
+
+        h6 {
+            font-size: 1em;
+        }
+
+        #toctitle {
+            font-size: 1.2em;
+        }
+
+        @media screen and (min-width: 768px) {
+            #toctitle {
+                font-size: 1.375em;
+            }
+        }
+
+        /* Media query for larger screens */
+        @media screen and (min-width: 768px) {
+            h1, h2, h3, h4, h5, h6 {
+                line-height: 1.2;
+            }
+
+            h1 {
+                font-size: 2.75em;
+            }
+
+            h2 {
+                font-size: 2.3125em;
+            }
+
+            h3 {
+                font-size: 1.6875em;
+            }
+
+            h4 {
+                font-size: 1.4375em;
+            }
+        }
+
+        /* Links */
+        a {
+            color: #2156a5;
+            text-decoration: underline;
+            line-height: inherit;
+        }
+
+        /* TOC styling */
+        #toc {
+            border-bottom: 1px solid #e7e7e9;
+            padding-bottom: .5em;
+        }
+
+        #header>h1:first-child+#toc {
+            margin-top: 8px;
+            border-top: 1px solid #dddddf;
+        }
+
+        #toc>ul {
+            margin-left: .125em;
+        }
+
+        #toc ul {
+            font-family: "Open Sans", "DejaVu Sans", sans-serif;
+            list-style-type: none;
+        }
+
+        #toc li {
+            line-height: 1.3334;
+            margin-top: .3334em;
+        }
+
+        #toc a {
+            text-decoration: none;
+        }
+
+        a:hover, a:focus {
+            color: #1d4b8f;
+        }
+
+        /* Lists */
+        ul, ol, dl {
+            line-height: 1.6;
+            margin-bottom: 1.25em;
+            list-style-position: outside;
+            font-family: inherit;
+            margin-left: 1.5em;
+        }
+
+        ul {
+            list-style: disc;
+        }
+
+        ul li ul, ul li ol {
+            margin-left: 1.25em;
+            margin-bottom: 0;
+        }
+
+        /* TOC section levels */
+        #toc ul.sectlevel0>li>a {
+            font-style: italic;
+        }
+
+        #toc ul.sectlevel0 ul.sectlevel1 {
+            margin: .5em 0;
+        }
+
+        @media screen and (min-width: 768px) {
+            #toc.toc2 ul ul {
+                margin-left: 0;
+                padding-left: 1em;
+            }
+
+            #toc.toc2 ul.sectlevel0 ul.sectlevel1 {
+                padding-left: 0;
+                margin-top: .5em;
+                margin-bottom: .5em;
+            }
+        }
+
+        @media screen and (min-width: 1280px) {
+            #toc.toc2 ul ul {
+                padding-left: 1.25em;
+            }
+        }
+
+        /* Responsive image handling at different screen sizes */
+        @media screen and (max-width: 768px) {
+            td.image-container {
+                max-width: 100%;
+                display: block;
+                margin: 1em auto;
+            }
+
+            table td[rowspan] {
+                display: table-cell;
+            }
+
+            img {
+                max-width: 100%;
+                height: auto;
+            }
+        }
+
+        /* Tables - more detailed styling */
+        table {
+            background: #fff;
+            margin-bottom: 1.25em;
+            border: 1px solid #dedede;
+            word-wrap: normal;
+            border-collapse: collapse;
+            border-spacing: 0;
+            width: 100%;
+        }
+
+        table thead, table tfoot {
+            background: #f7f8f7;
+        }
+
+        table thead tr th, table thead tr td, table tfoot tr th, table tfoot tr td {
+            padding: .5em .625em .625em;
+            font-size: inherit;
+            color: rgba(0,0,0,.8);
+            text-align: left;
+        }
+
+        table tr th, table tr td {
+            padding: .5625em .625em;
+            font-size: inherit;
+            color: rgba(0,0,0,.8);
+            line-height: 1.6;
+            border: 1px solid #dedede;
+        }
+
+        /* Anchor links styling */
+        #content h1>a.anchor,h2>a.anchor,h3>a.anchor,#toctitle>a.anchor,.sidebarblock>.content>.title>a.anchor,h4>a.anchor,h5>a.anchor,h6>a.anchor{
+            position:absolute;
+            z-index:1001;
+            width:1.5ex;
+            margin-left:-1.5ex;
+            display:block;
+            text-decoration:none!important;
+            visibility:hidden;
+            text-align:center;
+            font-weight:400
+        }
+
+        table tr.even, table tr.alt {
+            background: #f8f8f7;
+        }
+
+        /* Image container styling */
+        td.image-container {
+            vertical-align: middle;
+            text-align: center;
+            width: 40%;
+            max-width: 300px;
+        }
+
+        td.image-container img {
+            max-width: 100%;
+            height: auto;
+            object-fit: contain;
+        }
+
+        /* Text styling */
+        p {
+            line-height: 1.6;
+            margin-bottom: 1.25em;
+            text-rendering: optimizeLegibility;
+        }
+
+        strong, b {
+            font-weight: bold;
+            line-height: inherit;
+        }
+
+        em, i {
+            font-style: italic;
+            line-height: inherit;
+        }
+
+        /* Top navigation links - base style */
+        .top-link {
+            display: inline-block;
+            float: right;
+            font-size: 0.8em;
+            font-weight: normal;
+            text-transform: uppercase;
             color: #2156a5;
             text-decoration: none;
-            font-size: 12pt;
+            position: relative;
         }
-        ul {
-            padding-left: 0;
-            list-style: none;
+
+        /* Specific positioning for h2 headings */
+        .heading-container h2 + .top-link {
+            margin-top: 4.75em;
+            bottom: 0.3em;
         }
-        ul.subList {
-            padding-left: 20px;
+
+        /* Specific positioning for h3 headings */
+        .heading-container h3 + .top-link {
+            margin-top: 3.5em;
+            bottom: 0.3em;
         }
-        li.subItem {
-            padding-top: 5px;
+
+        /* Fallbacks in case the adjacent sibling selector doesn't work as expected */
+        .heading-container:has(h2) .top-link {
+            margin-top: 4.75em;
+        }
+
+        .heading-container:has(h3) .top-link {
+            margin-top: 3.5em;
+        }
+
+        /* Clearfix for headings with top links */
+        .heading-container {
+            overflow: hidden;
+            width: 100%;
+            position: relative;
+        }
+
+        .heading-container h2,
+        .heading-container h3 {
+            float: left;
+            margin-bottom: 0;
+        }
+
+        /* Hide top links when printing */
+        @media print {
+            .top-link {
+                display: none;
+            }
         }
     </style>
 </head>
 <body>
+    <div id="header" class="center-container">
     <h1>${headingLabel}: ${JobLabel}</h1>
-    <div id="toc">
-        <h2 class="ToC">${tableOfContentsLabel}</h2>
-        <ul>
-            <li><a class="customLink" href="#_part_information">${partInformationLabel}</a></li>
-            <li><a class="customLink" href="#_run_summary">${runSummaryLabel}</a></li>
-            <li><a class="customLink" href="#_rough_stock">${roughStockLabel}</a></li>
-            <li><a class="customLink" href="#_tool_data">${toolDataLabel}</a>
-                <ul class="subList">
+    <div id="toc" class="toc">
+        <div id="toctitle">${tableOfContentsLabel}</div>
+        <ul class="sectlevel1">
+            <li><a href="#_part_information">${partInformationLabel}</a></li>
+            <li><a href="#_run_summary">${runSummaryLabel}</a></li>
+            <li><a href="#_rough_stock">${roughStockLabel}</a></li>
+            <li><a href="#_tool_data">${toolDataLabel}</a>
+                <ul class="sectlevel2">
                     ${tool_list}
                 </ul>
             </li>
-            <li><a class="customLink" href="#_output">${outputLabel}</a></li>
-            <li><a class="customLink" href="#_fixtures_and_workholding">${fixturesLabel}</a></li>
-            <li><a class="customLink" href="#_squawks">${squawksLabel}</a></li>
+            <li><a href="#_output">${outputLabel}</a></li>
+            <li><a href="#_fixtures_and_workholding">${fixturesLabel}</a></li>
+            <li><a href="#_squawks">${squawksLabel}</a></li>
         </ul>
     </div>
 
 
-<h2 class="western"><a name="_part_information"></a>${partInformationLabel}</h2>
-<table cellpadding="2" cellspacing="2" bgcolor="#ffffff" style="background: #ffffff;">
+<div class="heading-container">
+    <h2 id="_part_information"><a name="_part_information"></a>${partInformationLabel}</h2><a href="#header" class="top-link">Top</a>
+</div>
+<table>
     <colgroup>
-        <col width="200"/>
-        <col width="525"/>
-        <col width="250"/>
+        <col width="20%"/>
+        <col width="50%"/>
+        <col width="30%"/>
     </colgroup>
-    <tr valign="top">
-        <td style="border: 1px solid #dedede; padding: 0.05cm;">
+    <tr>
+        <td>
             <strong>${PartLabel}</strong>
         </td>
         <td>
-            <table style="background-color: #ffffff;">
+            <table>
                 <colgroup>
-                    <col width="175"/>
-                    <col width="175"/>
+                    <col width="50%"/>
+                    <col width="50%"/>
                 </colgroup>
                 ${bases}
             </table>
         </td>
-        <td rowspan="7" style="border: 1px solid #dedede; padding: 0.05cm;">
+        <td rowspan="7" class="image-container">
             ${baseimage}
         </td>
     </tr>
     <tr>
-        <td style="border: 1px solid #dedede; padding: 0.05cm;">
+        <td>
             <strong>${SequenceLabel}</strong>
         </td>
-        <td style="border: 1px solid #dedede; padding: 0.05cm;">
+        <td>
             ${Sequence}
         </td>
     </tr>
 
     <tr>
-        <td style="border: 1px solid #dedede; padding: 0.05cm;">
+        <td>
             <strong>${JobTypeLabel}</strong>
         </td>
-        <td style="border: 1px solid #dedede; padding: 0.05cm;">
+        <td>
             ${JobType}
         </td>
     </tr>
     <tr>
-        <td style="border: 1px solid #dedede; padding: 0.05cm;">
+        <td>
             <strong>${CADLabel}</strong>
         </td>
-        <td style="border: 1px solid #dedede; padding: 0.05cm;">
+        <td>
             ${FileName}
         </td>
     </tr>
     <tr>
-        <td style="border: 1px solid #dedede; padding: 0.05cm;">
+        <td>
             <strong>${LastSaveLabel}</strong>
         </td>
-        <td style="border: 1px solid #dedede; padding: 0.05cm;">
+        <td>
             ${LastModifiedDate}
         </td>
     </tr>
     <tr>
-        <td style="border: 1px solid #dedede; padding: 0.05cm;">
+        <td>
             <strong>${CustomerLabel}</strong>
         </td>
-        <td style="border: 1px solid #dedede; padding: 0.05cm;">
+        <td>
             ${Customer}
         </td>
     </tr>
 </table>
 
-<h2 class="western"><a name="_run_summary"></a>${runSummaryLabel}</h2>
-<table cellpadding="2" cellspacing="2" bgcolor="#ffffff" style="background: #ffffff;">
+<div class="heading-container">
+    <h2 id="_run_summary"><a name="_run_summary"></a>${runSummaryLabel}</h2><a href="#header" class="top-link">Top</a>
+</div>
+<table>
     <colgroup>
-        <col width="210"/>
-        <col width="210"/>
-        <col width="210"/>
-        <col width="210"/>
-        <col width="210"/>
+        <col width="20%"/>
+        <col width="20%"/>
+        <col width="20%"/>
+        <col width="20%"/>
+        <col width="20%"/>
     </colgroup>
-    <tr>
-        <td style="border: 1px solid #dedede; padding: 0.05cm">
-            <strong>${opLabel}</strong>
-        </td>
-        <td style="border: 1px solid #dedede; padding: 0.05cm">
-            <strong>${jobMinZLabel}</strong>
-        </td>
-        <td style="border: 1px solid #dedede; padding: 0.05cm">
-            <strong>${jobMaxZLabel}</strong>
-        </td>
-        <td style="border: 1px solid #dedede; padding: 0.05cm">
-            <strong>${coolantLabel}</strong>
-        </td>
-        <td style="border: 1px solid #dedede; padding: 0.05cm">
-            <strong>${cycleTimeLabel}</strong>
-        </td>
-    </tr>
-    ${run_summary_ops}
+    <thead>
+        <tr>
+            <th><strong>${opLabel}</strong></th>
+            <th><strong>${jobMinZLabel}</strong></th>
+            <th><strong>${jobMaxZLabel}</strong></th>
+            <th><strong>${coolantLabel}</strong></th>
+            <th><strong>${cycleTimeLabel}</strong></th>
+        </tr>
+    </thead>
+    <tbody>
+        ${run_summary_ops}
+    </tbody>
 </table>
 
-<h2 class="western"><a name="_rough_stock"></a>${roughStockLabel}</h2>
+<div class="heading-container">
+    <h2 id="_rough_stock"><a name="_rough_stock"></a>${roughStockLabel}</h2><a href="#header" class="top-link">Top</a>
+</div>
 
-<table cellpadding="2" cellspacing="2" bgcolor="#ffffff" style="background: #ffffff;">
+<table>
     <colgroup>
-        <col width="350"/>
-        <col width="350"/>
-        <col width="350"/>
+        <col width="30%"/>
+        <col width="30%"/>
+        <col width="40%"/>
     </colgroup>
-    <tr>
-        <td style="border: 1px solid #dedede; padding: 0.05cm"><strong>${materialLabel}</strong></td>
-        <td style="border: 1px solid #dedede; padding: 0.05cm">${material}</td>
-        <td rowspan="7" style="border: 1px solid #dedede; padding: 0.05cm">
-            ${stockImage}
-        </td>
+    <tbody>
+        <tr>
+            <td><strong>${materialLabel}</strong></td>
+            <td>${material}</td>
+            <td rowspan="7" class="image-container">
+                ${stockImage}
+            </td>
+        </tr>
+        <tr>
+            <td><strong>${sSpeedHSSLabel}</strong></td>
+            <td>${surfaceSpeedHSS}</td>
+        </tr>
+        <tr>
+            <td><strong>${sSpeedCarbideLabel}</strong></td>
+        <td>${surfaceSpeedCarbide}</td>
     </tr>
     <tr>
-        <td style="border: 1px solid #dedede; padding: 0.05cm"><strong>${sSpeedHSSLabel}</strong></td>
-        <td style="border: 1px solid #dedede; padding: 0.05cm">${surfaceSpeedHSS}</td>
+        <td><strong>${xDimLabel}</strong></td>
+        <td>${xLen}</td>
     </tr>
     <tr>
-        <td style="border: 1px solid #dedede; padding: 0.05cm"><strong>${sSpeedCarbideLabel}</strong></td>
-        <td style="border: 1px solid #dedede; padding: 0.05cm">${surfaceSpeedCarbide}</td>
+        <td><strong>${yDimLabel}</strong></td>
+        <td>${yLen}</td>
     </tr>
     <tr>
-        <td style="border: 1px solid #dedede; padding: 0.05cm"><strong>${xDimLabel}</strong></td>
-        <td style="border: 1px solid #dedede; padding: 0.05cm">${xLen}</td>
-    </tr>
-    <tr>
-        <td style="border: 1px solid #dedede; padding: 0.05cm"><strong>${yDimLabel}</strong></td>
-        <td style="border: 1px solid #dedede; padding: 0.05cm">${yLen}</td>
-    </tr>
-    <tr>
-        <td style="border: 1px solid #dedede; padding: 0.05cm"><strong>${zDimLabel}</strong></td>
-        <td style="border: 1px solid #dedede; padding: 0.05cm">${zLen}</td>
+        <td><strong>${zDimLabel}</strong></td>
+        <td>${zLen}</td>
     </tr>
 </table>
 
 
-<h2 class="western"><a name="_tool_data"></a>${toolDataLabel}</h2>
+<div class="heading-container">
+    <h2 id="_tool_data"><a name="_tool_data"></a>${toolDataLabel}</h2><a href="#header" class="top-link">Top</a>
+</div>
 ${tool_data}
 
 
-<h2 class="western"><a name="_output"></a>${outputLabel}</h2>
+<div class="heading-container">
+    <h2 id="_output"><a name="_output"></a>${outputLabel}</h2><a href="#header" class="top-link">Top</a>
+</div>
 <table cellpadding="2" cellspacing="2" bgcolor="#ffffff" style="background: #ffffff;">
     <colgroup>
         <col width="525"/>
         <col width="525"/>
     </colgroup>
     <tr>
-        <td style="border: 1px solid #dedede; padding: 0.05cm">
+        <td>
             <strong>${gcodeFileLabel}</strong>
         </td>
-        <td style="border: 1px solid #dedede; padding: 0.05cm">
+        <td>
             ${lastgcodefile}
         </td>
     </tr>
     <tr>
-        <td style="border: 1px solid #dedede; padding: 0.05cm">
+        <td>
             <strong>${lastpostLabel}</strong>
         </td>
-        <td style="border: 1px solid #dedede; padding: 0.05cm">
+        <td>
             ${lastpostprocess}
         </td>
     </tr>
     <tr>
-        <td style="border: 1px solid #dedede; padding: 0.05cm">
+        <td>
             <strong>${stopsLabel}</strong>
         </td>
-        <td style="border: 1px solid #dedede; padding: 0.05cm">
+        <td>
             ${optionalstops}
         </td>
     </tr>
     <tr>
-        <td style="border: 1px solid #dedede; padding: 0.05cm">
+        <td>
             <strong>${programmerLabel}</strong>
         </td>
-        <td style="border: 1px solid #dedede; padding: 0.05cm">
+        <td>
             ${programmer}
         </td>
     </tr>
     <tr>
-        <td style="border: 1px solid #dedede; padding: 0.05cm">
+        <td>
             <strong>${machineLabel}</strong>
         </td>
-        <td style="border: 1px solid #dedede; padding: 0.05cm">
+        <td>
             ${machine}
         </td>
     </tr>
     <tr>
-        <td style="border: 1px solid #dedede; padding: 0.05cm">
+        <td>
             <strong>${postLabel}</strong>
         </td>
-        <td style="border: 1px solid #dedede; padding: 0.05cm">
+        <td>
             ${postprocessor}
         </td>
     </tr>
     <tr>
-        <td style="border: 1px solid #dedede; padding: 0.05cm">
+        <td>
             <strong>${flagsLabel}</strong>
         </td>
-        <td style="border: 1px solid #dedede; padding: 0.05cm">
+        <td>
             ${postprocessorFlags}
         </td>
     </tr>
     <tr>
-        <td style="border: 1px solid #dedede; padding: 0.05cm">
+        <td>
             <strong>${fileSizeLabel}</strong>
         </td>
-        <td style="border: 1px solid #dedede; padding: 0.05cm">
+        <td>
             ${filesize}
         </td>
     </tr>
     <tr>
-        <td style="border: 1px solid #dedede; padding: 0.05cm">
+        <td>
             <strong>${lineCountLabel}</strong>
         </td>
-        <td style="border: 1px solid #dedede; padding: 0.05cm">
+        <td>
             ${linecount}
         </td>
     </tr>
 </table>
 
-<h2 class="western"><a name="_fixtures_and_workholding"></a>${fixturesLabel}</h2>
+<div class="heading-container">
+    <h2 id="_fixtures_and_workholding"><a name="_fixtures_and_workholding"></a>${fixturesLabel}</h2><a href="#header" class="top-link">Top</a>
+</div>
 <table cellpadding="2" cellspacing="2" bgcolor="#ffffff" style="background: #ffffff;">
     <colgroup>
         <col width="525"/>
         <col width="525"/>
     </colgroup>
     <tr>
-        <td style="border: 1px solid #dedede; padding: 0.05cm">
+        <td>
             <strong>${offsetsLabel}</strong>
         </td>
-        <td style="border: 1px solid #dedede; padding: 0.05cm">
+        <td>
             ${fixtures}
         </td>
     </tr>
     <tr>
-        <td style="border: 1px solid #dedede; padding: 0.05cm">
+        <td>
             <strong>${orderByLabel}</strong>
         </td>
-        <td style="border: 1px solid #dedede; padding: 0.05cm">
+        <td>
             ${orderBy}
         </td>
     </tr>
     <tr>
-        <td style="border: 1px solid #dedede; padding: 0.05cm">
+        <td>
             <strong>${datumLabel}</strong>
         </td>
-        <td style="border: 1px solid #dedede; padding: 0.05cm">
+        <td class="image-container">
             ${datumImage}
         </td>
     </tr>
 </table>
 
-<h2 class="western"><a name="_squawks"></a>${squawksLabel}</h2>
+<div class="heading-container">
+    <h2 id="_squawks"><a name="_squawks"></a>${squawksLabel}</h2><a href="#header" class="top-link">Top</a>
+</div>
 <table cellpadding="2" cellspacing="2" bgcolor="#ffffff" style="background-color: #ffffff;">
     <colgroup>
         <col width="100"/>
@@ -339,16 +663,16 @@ ${tool_data}
         <col width="550"/>
     </colgroup>
     <tr>
-        <td style="border: 1px solid #dedede; padding: 0.05cm">
+        <td>
             <strong>${noteLabel}</strong>
         </td>
-        <td style="border: 1px solid #dedede; padding: 0.05cm">
+        <td>
             <strong>${operatorLabel}</strong>
         </td>
-        <td style="border: 1px solid #dedede; padding: 0.05cm">
+        <td>
             <strong>${dateLabel}</strong>
         </td>
-        <td style="border: 1px solid #dedede; padding: 0.05cm">
+        <td>
             <strong>${noteLabel}</strong>
         </td>
         ${squawks}
@@ -356,8 +680,8 @@ ${tool_data}
 </table>
 
 <p style="line-height: 100%; margin-bottom: 0cm"><br/>
-
 </p>
+</div>
 </body>
 </html>
 """
@@ -366,11 +690,11 @@ ${tool_data}
 base_template = Template(
     """
 <tr>
-    <td style='border: 1px solid #dedede; padding: 0.05cm;'>
-        %{key}
+    <td>
+        ${key}
     </td>
-    <td style='border: 1px solid #dedede; padding: 0.05cm;'>
-        %{val}
+    <td>
+        ${val}
     </td>
 </tr>
         """
@@ -379,16 +703,16 @@ base_template = Template(
 squawk_template = Template(
     """
 <tr>
-    <td style="border: 1px solid #dedede; padding: 0.05cm">
+    <td>
         ${squawkIcon}
     </td>
-    <td style="border: 1px solid #dedede; padding: 0.05cm">
+    <td>
         ${Operator}
     </td>
-    <td style="border: 1px solid #dedede; padding: 0.05cm">
+    <td>
         ${Date}
     </td>
-    <td style="border: 1px solid #dedede; padding: 0.05cm" colspan="3">
+    <td colspan="3">
         ${Note}
     </td>
 </tr>
@@ -397,68 +721,71 @@ squawk_template = Template(
 
 tool_template = Template(
     """
-<table cellpadding="2" cellspacing="2" bgcolor="#ffffff" style="background: #ffffff;">
+<div class="heading-container">
+    <h3 id="_tool_data_T${toolNumber}">Tool Number: T${toolNumber}</h3><a href="#header" class="top-link">Top</a>
+</div>
+<table>
     <colgroup>
-        <col width="350"/>
-        <col width="350"/>
-        <col width="350"/>
+        <col width="30%"/>
+        <col width="30%"/>
+        <col width="40%"/>
     </colgroup>
     <tr>
-        <td style="border: 1px solid #dedede; padding: 0.05cm">
+        <td>
             <strong>${descriptionLabel}</strong>
         </td>
-        <td style="border: 1px solid #dedede; padding: 0.05cm">
+        <td>
             ${description}
         </td>
-        <td style="border: 1px solid #dedede; padding: 0.05cm">
+        <td class="image-container">
             ${imagepath}
         </td>
     </tr>
     <tr>
-        <td style="border: 1px solid #dedede; padding: 0.05cm">
+        <td>
             <strong>${manufLabel}</strong>
         </td>
-        <td style="border: 1px solid #dedede; padding: 0.05cm" colspan="2">
+        <td colspan="2">
             ${manufacturer}
         </td>
     </tr>
     <tr>
-        <td style="border: 1px solid #dedede; padding: 0.05cm">
+        <td>
             <strong>${partNumberLabel}</strong>
         </td>
-        <td style="border: 1px solid #dedede; padding: 0.05cm" colspan="2">
+        <td colspan="2">
             ${partNumber}
         </td>
     </tr>
     <tr>
-        <td style="border: 1px solid #dedede; padding: 0.05cm">
+        <td>
             <strong>${urlLabel}</strong>
         </td>
-        <td style="border: 1px solid #dedede; padding: 0.05cm" colspan="2">
+        <td colspan="2">
             ${url}
         </td>
     </tr>
     <tr>
-        <td style="border: 1px solid #dedede; padding: 0.05cm">
+        <td>
             <strong>${shapeLabel}</strong>
         </td>
-        <td style="border: 1px solid #dedede; padding: 0.05cm" colspan="2">
+        <td colspan="2">
             ${shape}
         </td>
     </tr>
     <tr>
-        <td style="border: 1px solid #dedede; padding: 0.05cm">
+        <td>
             <strong>${inspectionNotesLabel}</strong>
         </td>
-        <td style="border: 1px solid #dedede; padding: 0.05cm" colspan="2">
+        <td colspan="2">
             ${inspectionNotes}
         </td>
     </tr>
     <tr>
-        <td style="border: 1px solid #dedede; padding: 0.05cm">
+        <td>
             <strong>${diameterLabel}</strong>
         </td>
-        <td style="border: 1px solid #dedede; padding: 0.05cm" colspan="2">
+        <td colspan="2">
             ${diameter}
         </td>
     </tr>
@@ -477,30 +804,30 @@ op_tool_template = Template(
         <col width="262"/>
     </colgroup>
     <tr>
-        <td style="border: 1px solid #dedede; padding: 0.05cm">
+        <td>
             <strong>${opLabel}</strong>
         </td>
-        <td style="border: 1px solid #dedede; padding: 0.05cm">
+        <td>
             <strong>${tcLabel}</strong>
         </td>
-        <td style="border: 1px solid #dedede; padding: 0.05cm">
+        <td>
             <strong>${feedLabel}</strong>
         </td>
-        <td style="border: 1px solid #dedede; padding: 0.05cm">
+        <td>
             <strong>${speedLabel}</strong>
         </td>
     </tr>
     <tr>
-        <td style="border: 1px solid #dedede; padding: 0.05cm">
+        <td>
             ${Operation}
         </td>
-        <td style="border: 1px solid #dedede; padding: 0.05cm">
+        <td>
             ${ToolController}
         </td>
-        <td style="border: 1px solid #dedede; padding: 0.05cm">
+        <td>
             ${Feed}
         </td>
-        <td style="border: 1px solid #dedede; padding: 0.05cm">
+        <td>
             ${Speed}
         </td>
     </tr>
@@ -511,19 +838,19 @@ op_tool_template = Template(
 op_run_template = Template(
     """
 <tr>
-    <td style="border: 1px solid #dedede; padding: 0.05cm">
+    <td>
         ${opName}
     </td>
-    <td style="border: 1px solid #dedede; padding: 0.05cm">
+    <td>
         ${minZ}
     </td>
-    <td style="border: 1px solid #dedede; padding: 0.05cm">
+    <td>
         ${maxZ}
     </td>
-    <td style="border: 1px solid #dedede; padding: 0.05cm">
+    <td>
         ${coolantMode}
     </td>
-    <td style="border: 1px solid #dedede; padding: 0.05cm">
+    <td>
         ${cycleTime}
     </td>
 </tr>
@@ -532,6 +859,6 @@ op_run_template = Template(
 
 tool_item_template = Template(
     """
-<li class="subItem"><a class="customLink" href="#_tool_data_T${toolNumber}">T${toolNumber}-${description}</a></li>
+<li><a href="#_tool_data_T${toolNumber}">Tool Number: T${toolNumber}</a></li>
     """
 )
diff --git a/src/Mod/CAM/Path/Main/Sanity/ImageBuilder.py b/src/Mod/CAM/Path/Main/Sanity/ImageBuilder.py
index c023c887d0..2262683390 100644
--- a/src/Mod/CAM/Path/Main/Sanity/ImageBuilder.py
+++ b/src/Mod/CAM/Path/Main/Sanity/ImageBuilder.py
@@ -1,5 +1,6 @@
 # ***************************************************************************
 # *   Copyright (c) 2024 Ondsel <development@ondsel.com>                    *
+# *   Copyright (c) 2025 Billy Huddleston <billy@ivdc.com>                  *
 # *                                                                         *
 # *   This file is part of the FreeCAD CAx development system.              *
 # *                                                                         *
@@ -21,12 +22,13 @@
 # *                                                                         *
 # ***************************************************************************
 
-from PySide import QtGui
+from PySide import QtGui, QtCore
 import FreeCAD
 import FreeCADGui
 import Path.Log
 import os
-import time
+import tempfile
+
 
 if False:
     Path.Log.setLevel(Path.Log.Level.DEBUG, Path.Log.thisModule())
@@ -39,7 +41,7 @@ class ImageBuilder:
     def __init__(self, file_path):
         self.file_path = file_path
 
-    def build_image(self, obj, image_name):
+    def build_image(self, obj, image_name, as_bytes=False, view="default"):
         raise NotImplementedError("Subclass must implement abstract method")
 
     def save_image(self, image):
@@ -49,7 +51,6 @@ class ImageBuilder:
 class ImageBuilderFactory:
     @staticmethod
     def get_image_builder(file_path, **kwargs):
-
         # return DummyImageBuilder(file_path, **kwargs)
         if FreeCAD.GuiUp:
             return GuiImageBuilder(file_path, **kwargs)
@@ -63,7 +64,9 @@ class DummyImageBuilder(ImageBuilder):
         Path.Log.debug("Initializing dummyimagebuilder")
         super().__init__(file_path)
 
-    def build_image(self, obj, imageName):
+    def build_image(self, obj, imageName, as_bytes=False, view="default"):
+        if as_bytes:
+            return b""
         return self.file_path
 
 
@@ -85,7 +88,7 @@ class GuiImageBuilder(ImageBuilder):
         Path.Log.debug("Destroying GuiImageBuilder")
         self.restore_visibility()
 
-    def prepare_view(self, obj):
+    def prepare_view(self, obj, view="default"):
         # Create a new view
         Path.Log.debug("CAM - Preparing view\n")
 
@@ -93,10 +96,13 @@ class GuiImageBuilder(ImageBuilder):
         num_windows = len(mw.getWindows())
 
         # Create and configure the view
-        view = FreeCADGui.ActiveDocument.createView("Gui::View3DInventor")
-        view.setAnimationEnabled(False)
-        view.viewIsometric()
-        view.setCameraType("Perspective")
+        view_obj = FreeCADGui.ActiveDocument.createView("Gui::View3DInventor")
+        view_obj.setAnimationEnabled(False)
+        view_obj.setCameraType("Orthographic")
+        if view == "headon":
+            view_obj.viewFront()
+        else:
+            view_obj.viewIsometric()
 
         # Resize the window
         mdi = mw.findChild(QtGui.QMdiArea)
@@ -104,10 +110,24 @@ class GuiImageBuilder(ImageBuilder):
         view_window.resize(500, 500)
         view_window.showMaximized()
 
-        FreeCADGui.Selection.clearSelection()
-
+        # First make everything invisible
         self.record_visibility()
+
+        # Then make only our target object visible and select it
         obj.Visibility = True
+        FreeCADGui.Selection.clearSelection()
+        FreeCADGui.Selection.addSelection(obj)
+        FreeCADGui.Selection.clearSelection()  # Clear so the selection highlight does not appear in the image
+
+        # Get the active view and fit to selection
+        a_view = FreeCADGui.activeDocument().activeView()
+        try:
+            a_view.fitAll()  # First fit all to ensure the object is in view
+            FreeCADGui.updateGui()
+            a_view.fitSelection()  # Then try to fit to the selection
+        except Exception:
+            # If fitSelection fails, we already called fitAll
+            pass
 
         # Return the index of the new window (= old number of windows)
         return num_windows
@@ -128,41 +148,90 @@ class GuiImageBuilder(ImageBuilder):
         for o in self.visible:
             o.Visibility = True
 
-    def build_image(self, obj, image_name):
+    def build_image(self, obj, image_name, as_bytes=False, view="default"):
         Path.Log.debug("CAM - Building image\n")
         """
-        Makes an image of the target object.  Returns filename.
+        Makes an image of the target object. Returns either the image as bytes or a filename.
         """
 
-        file_path = os.path.join(self.file_path, image_name)
+        idx = self.prepare_view(obj, view=view)
 
-        idx = self.prepare_view(obj)
-
-        self.capture_image(file_path)
-        self.destroy_view(idx)
-
-        result = f"{file_path}_t.png"
-
-        Path.Log.debug(f"Saving image to: {file_path}")
-        Path.Log.debug(f"Image saved to: {result}")
-        return result
+        if as_bytes:
+            # Capture directly to memory without writing to disk
+            img_bytes = self.capture_image_to_bytes()
+            self.destroy_view(idx)
+            return img_bytes
+        else:
+            # Write to disk as before
+            file_path = os.path.join(self.file_path, image_name)
+            self.capture_image(file_path)
+            self.destroy_view(idx)
+            result = f"{file_path}_t.png"
+            Path.Log.debug(f"Image saved to: {result}")
+            return result
 
     def capture_image(self, file_path):
-
         FreeCADGui.updateGui()
-        Path.Log.debug("CAM - capture image\n")
+        Path.Log.debug("CAM - capture image to file\n")
         a_view = FreeCADGui.activeDocument().activeView()
-        a_view.saveImage(file_path + ".png", 500, 500, "Current")
-        a_view.saveImage(file_path + "_t.png", 500, 500, "Transparent")
+        # Generate higher resolution images - 800x800 pixels for better quality on high-DPI displays
+        a_view.saveImage(file_path + ".png", 800, 800, "Current")
+        a_view.saveImage(file_path + "_t.png", 800, 800, "Transparent")
         a_view.setAnimationEnabled(True)
 
+    def capture_image_to_bytes(self):
+        """Capture the current view directly to bytes without writing to disk"""
+        FreeCADGui.updateGui()
+        Path.Log.debug("CAM - capture image to bytes\n")
+        a_view = FreeCADGui.activeDocument().activeView()
+
+        try:
+            # Use FreeCAD's built-in method for getting a QImage directly
+            # This approach is based on the same method the viewport uses internally
+            qimg = a_view.grabFramebuffer()
+
+            # Convert QImage to bytes using QBuffer (purely in memory)
+            buffer = QtCore.QBuffer()
+            buffer.open(QtCore.QIODevice.WriteOnly)
+            qimg.save(buffer, "PNG")
+            img_bytes = buffer.data().data()
+            buffer.close()
+
+            a_view.setAnimationEnabled(True)
+            return img_bytes
+
+        except Exception as e:
+            # Fallback to temporary file approach if the direct method fails
+            Path.Log.debug(f"Direct image capture failed: {e}, using fallback method")
+
+            with tempfile.NamedTemporaryFile(suffix=".png", delete=False) as temp:
+                temp_path = temp.name
+
+            # saveImage doesn't write to memory directly, so we need to use a temporary file
+            # Generate higher resolution images - 800x800 pixels for better quality on high-DPI displays
+            a_view.saveImage(temp_path, 800, 800, "Transparent")
+
+            # Read the temporary file into memory
+            with open(temp_path, "rb") as f:
+                img_bytes = f.read()
+
+            # Clean up the temporary file
+            try:
+                os.unlink(temp_path)
+            except Exception:
+                # Ignore errors during temporary file cleanup, as failure to delete is non-critical
+                pass
+
+            a_view.setAnimationEnabled(True)
+            return img_bytes
+
 
 class NonGuiImageBuilder(ImageBuilder):
     def __init__(self, file_path):
         super().__init__(file_path)
         Path.Log.debug("nonguiimagebuilder")
 
-    def build_image(self, obj, image_name):
+    def build_image(self, obj, image_name, as_bytes=False, view="default"):
         """
         Generates a headless picture of a 3D object and saves it as a PNG and optionally a PostScript file.
 
@@ -212,20 +281,20 @@ class NonGuiImageBuilder(ImageBuilder):
             root.ref()
             ret = off.render(root)
             root.unref()
-
-            # Saving the rendered image
-            if off.isWriteSupported("PNG"):
-                file_path = f"{self.file_path}{os.path.sep}{imageName}.png"
-                off.writeToFile(file_path, "PNG")
+            if as_bytes:
+                qimg = off.getQImage()
+                buffer = QtCore.QBuffer()
+                buffer.open(QtCore.QIODevice.WriteOnly)
+                qimg.save(buffer, "PNG")
+                return buffer.data().data()
             else:
-                Path.Log.debug("PNG format is not supported.")
-                # return False
-
-            # Optionally save as PostScript if supported
-            file_path = f"{self.file_path}{os.path.sep}{imageName}.ps"
-            off.writeToPostScript(ps_file_path)
-
-            return file_path
+                if off.isWriteSupported("PNG"):
+                    file_path = f"{self.file_path}{os.path.sep}{image_name}.png"
+                    off.writeToFile(file_path, "PNG")
+                    return file_path
+                else:
+                    Path.Log.debug("PNG format is not supported.")
+                    return False
 
         except Exception as e:
             print(f"An error occurred: {e}")
diff --git a/src/Mod/CAM/Path/Main/Sanity/ReportGenerator.py b/src/Mod/CAM/Path/Main/Sanity/ReportGenerator.py
index 01796a75aa..ea636fd7c6 100644
--- a/src/Mod/CAM/Path/Main/Sanity/ReportGenerator.py
+++ b/src/Mod/CAM/Path/Main/Sanity/ReportGenerator.py
@@ -1,6 +1,7 @@
 # -*- coding: utf-8 -*-
 # ***************************************************************************
 # *   Copyright (c) 2024 Ondsel <development@ondsel.com>                    *
+# *   Copyright (c) 2025 Billy Huddleston <billy@ivdc.com>                  *
 # *                                                                         *
 # *   This program is free software; you can redistribute it and/or modify  *
 # *   it under the terms of the GNU Lesser General Public License (LGPL)    *
@@ -46,6 +47,18 @@ else:
 
 
 class ReportGenerator:
+    def bytes_to_base64_with_tag(self, image_bytes, mime_type="image/png", alt="Image"):
+        """
+        Takes image bytes and returns (base64_string, <img> tag) for embedding in HTML.
+        Default mime_type is image/png.
+        """
+
+        if not image_bytes:
+            return "", ""
+        encoded_string = base64.b64encode(image_bytes).decode()
+        html_tag = f'<img src="data:{mime_type};base64,{encoded_string}" alt="{alt}" />'
+        return encoded_string, html_tag
+
     def __init__(self, data, embed_images=False):
         self.embed_images = embed_images
         self.squawks = ""
@@ -128,7 +141,12 @@ class ReportGenerator:
                     Path.Log.debug(f"key: {key} val: {val}")
                     if self.embed_images:
                         Path.Log.debug("Embedding images")
-                        encoded_image, tag = self.file_to_base64_with_tag(val)
+                        if isinstance(val, bytes):
+                            encoded_image, tag = self.bytes_to_base64_with_tag(
+                                val, mime_type="image/png", alt=key
+                            )
+                        else:
+                            encoded_image, tag = self.file_to_base64_with_tag(val)
                     else:
                         Path.Log.debug("Not Embedding images")
                         tag = f"<img src={val} name='Image' alt={key} />"
@@ -140,13 +158,20 @@ class ReportGenerator:
         for key, val in data["toolData"].items():
             if key == "squawkData":
                 self._format_squawks(val)
-            # else:
-            #     self._format_tool(key, val)
-
             else:
                 toolNumber = key
                 toolAttributes = val
-                if "imagepath" in toolAttributes and toolAttributes["imagepath"] != "":
+                # Prefer imagebytes for embedding if present
+                if (
+                    self.embed_images
+                    and "imagebytes" in toolAttributes
+                    and toolAttributes["imagebytes"]
+                ):
+                    _, tag = self.bytes_to_base64_with_tag(
+                        toolAttributes["imagebytes"], mime_type="image/png", alt=key
+                    )
+                    toolAttributes["imagepath"] = tag
+                elif "imagepath" in toolAttributes and toolAttributes["imagepath"] != "":
                     if self.embed_images:
                         encoded_image, tag = self.file_to_base64_with_tag(
                             toolAttributes["imagepath"]
@@ -165,7 +190,6 @@ class ReportGenerator:
         # Path.Log.debug(self.formatted_data)
 
     def _format_tool_list(self, tool_data):
-
         tool_list = ""
         for key, val in tool_data.items():
             if key == "squawkData":
@@ -181,6 +205,8 @@ class ReportGenerator:
 
     def _format_tool(self, tool_number, tool_data):
         td = {}
+        td["toolNumber"] = tool_number
+
         for key, val in tool_data.items():
             if key == "squawkData":
                 self._format_squawks(val)
@@ -200,8 +226,8 @@ class ReportGenerator:
 
     def _format_bases(self, base_data):
         bases = ""
-        for base in base_data:
-            bases += base_template.substitute(base)
+        for key, val in base_data.items():
+            bases += base_template.substitute({"key": key, "val": val})
         self.formatted_data["bases"] = bases
 
     def _format_squawks(self, squawk_data):
diff --git a/src/Mod/CAM/Path/Main/Sanity/Sanity.py b/src/Mod/CAM/Path/Main/Sanity/Sanity.py
index 14aa2a0bea..81bb2a0046 100644
--- a/src/Mod/CAM/Path/Main/Sanity/Sanity.py
+++ b/src/Mod/CAM/Path/Main/Sanity/Sanity.py
@@ -1,6 +1,7 @@
 # -*- coding: utf-8 -*-
 # ***************************************************************************
 # *   Copyright (c) 2016 sliptonic <shopinthewoods@gmail.com>               *
+# *   Copyright (c) 2025 Billy Huddleston <billy@ivdc.com>                  *
 # *                                                                         *
 # *   This file is part of the FreeCAD CAx development system.              *
 # *                                                                         *
@@ -36,7 +37,6 @@ import Path.Log
 import Path.Main.Sanity.ImageBuilder as ImageBuilder
 import Path.Main.Sanity.ReportGenerator as ReportGenerator
 import os
-import tempfile
 import Path.Dressup.Utils as PathDressup
 
 translate = FreeCAD.Qt.translate
@@ -49,6 +49,9 @@ else:
 
 
 class CAMSanity:
+    # Toggle: True = use thumbnail, False = always use fallback image
+    USE_TOOL_THUMBNAIL = False
+
     """
     This class has the functionality to harvest data from a CAM Job
     and export it in a format that is useful to the user.
@@ -102,8 +105,9 @@ class CAMSanity:
 
         path = f"{FreeCAD.getHomePath()}Mod/CAM/Path/Main/Sanity/{squawk_icon}.svg"
 
+        local_date_str = date.strftime("%c")
         squawk = {
-            "Date": str(date),
+            "Date": local_date_str,
             "Operator": operator,
             "Note": note,
             "squawkType": squawkType,
@@ -120,7 +124,9 @@ class CAMSanity:
             [obj.Proxy.baseObject(obj, o).Label for o in obj.Model.Group]
         ).items():
             bases[name] = str(count)
-        data["baseimage"] = self.image_builder.build_image(obj.Model, "baseimage")
+            data["baseimage"] = self.image_builder.build_image(
+                obj.Model, "baseimage", as_bytes=True
+            )
         data["bases"] = bases
 
         return data
@@ -146,7 +152,15 @@ class CAMSanity:
         data["FileName"] = obj.Document.FileName
         data["LastModifiedDate"] = str(obj.Document.LastModifiedDate)
         data["Customer"] = obj.Document.Company
-        data["Designer"] = obj.Document.LastModifiedBy
+        lastmod = obj.Document.LastModifiedDate
+        if lastmod:
+            try:
+                # Parse ISO 8601 string and format
+                data["LastModifiedDate"] = datetime.fromisoformat(str(lastmod)).strftime("%c")
+            except Exception:
+                data["LastModifiedDate"] = str(lastmod)
+        else:
+            data["LastModifiedDate"] = ""
         data["JobDescription"] = obj.Description
         data["JobLabel"] = obj.Label
 
@@ -170,7 +184,7 @@ class CAMSanity:
         data["fixtures"] = str(obj.Fixtures)
         data["orderBy"] = str(obj.OrderOutputBy)
 
-        data["datumImage"] = self.image_builder.build_image(obj, "datumImage")
+        data["datumImage"] = self.image_builder.build_image(obj, "datumImage", as_bytes=True)
 
         return data
 
@@ -337,7 +351,7 @@ class CAMSanity:
                 )
             )
 
-        data["stockImage"] = self.image_builder.build_image(obj.Stock, "stockImage")
+        data["stockImage"] = self.image_builder.build_image(obj.Stock, "stockImage", as_bytes=True)
 
         return data
 
@@ -384,34 +398,49 @@ class CAMSanity:
             tooldata["manufacturer"] = ""
             tooldata["url"] = ""
             tooldata["inspectionNotes"] = ""
-            tooldata["diameter"] = str(TC.Tool.Diameter)
+            tooldata["diameter"] = str(TC.Tool.Diameter.UserString)
             tooldata["shape"] = TC.Tool.ShapeType
 
             tooldata["partNumber"] = ""
 
-            if os.path.isfile(TC.Tool.ShapeType):
-                imagedata = TC.Tool.Proxy.get_thumbnail()
-            else:
-                imagedata = None
-                data["squawkData"].append(
-                    self.squawk(
-                        "CAMSanity",
-                        translate("CAM_Sanity", "Toolbit Shape for TC: {} not found").format(
-                            TC.ToolNumber
-                        ),
-                        squawkType="WARNING",
+            # Use the toggle to determine which image to use
+            imagebytes = None
+            if self.USE_TOOL_THUMBNAIL:
+                # Try to get the thumbnail
+                thumb_bytes = None
+                if hasattr(TC.Tool, "Proxy") and hasattr(TC.Tool.Proxy, "get_thumbnail"):
+                    try:
+                        thumb_bytes = TC.Tool.Proxy.get_thumbnail()
+                    except Exception:
+                        thumb_bytes = None
+                if thumb_bytes:
+                    imagebytes = thumb_bytes
+                else:
+                    # Warn and use fallback head-on image
+                    data["squawkData"].append(
+                        self.squawk(
+                            "CAMSanity",
+                            translate("CAM_Sanity", "Toolbit Shape for TC: {} not found").format(
+                                TC.ToolNumber
+                            ),
+                            squawkType="WARNING",
+                        )
                     )
+                    imagebytes = self.image_builder.build_image(
+                        TC.Tool, f"T{TC.ToolNumber}", as_bytes=True, view="headon"
+                    )
+            else:
+                # Always use fallback head-on image
+                imagebytes = self.image_builder.build_image(
+                    TC.Tool, f"T{TC.ToolNumber}", as_bytes=True, view="headon"
                 )
-            tooldata["image"] = ""
+            tooldata["imagebytes"] = imagebytes
             imagepath = os.path.join(self.filelocation, f"T{TC.ToolNumber}.png")
             tooldata["imagepath"] = imagepath
             Path.Log.debug(imagepath)
-            if imagedata is not None:
-                with open(imagepath, "wb") as fd:
-                    fd.write(imagedata)
-                    fd.close()
+            # No longer writing imagedata to disk; handled by imagebytes logic above
 
-            tooldata["feedrate"] = str(TC.HorizFeed)
+            tooldata["feedrate"] = str(TC.HorizFeed.UserString)
             if TC.HorizFeed.Value == 0.0:
                 data["squawkData"].append(
                     self.squawk(
@@ -423,7 +452,7 @@ class CAMSanity:
                     )
                 )
 
-            tooldata["spindlespeed"] = str(TC.SpindleSpeed)
+            tooldata["spindlespeed"] = f"{int(TC.SpindleSpeed)} rpm"
             if TC.SpindleSpeed == 0.0:
                 data["squawkData"].append(
                     self.squawk(
@@ -444,8 +473,8 @@ class CAMSanity:
                         {
                             "Operation": base_op.Label,
                             "ToolController": TC.Label,
-                            "Feed": str(TC.HorizFeed),
-                            "Speed": str(TC.SpindleSpeed),
+                            "Feed": str(TC.HorizFeed.UserString),
+                            "Speed": f"{int(TC.SpindleSpeed)} rpm",
                         }
                     )