@CraigBroady It would be unfair to you and your companies work for me to suggest that the problems I have had are attributable to imperfections of the laser in my unit at this time. I have more testing to do and it will be a while before I can really get into it.
Since you opened the floor to suggestions I would like to add something. Laser printers do more or less what your product does only with out any user apparent signs of this kind of issue. I know that is a bit of an over simplification but bear with me here. As far as I can tell the secret to their sucess is the use of an F-Theta Lense. If you had one between the main mirror and the underside of the resin tank it might improve things. If that sounds to expenive just try curving the underside of the resin tank to form an f-theta lense. I favor the former because it means less disposable plastic and people would no longer be able to spill resin or what ever else onto the main mirror.