I’ve been running lots and lots of tests to try and characterise the effects of laser flare. Basically it’s as previously described by @Monger_Designs and @RocusHalbasch - in that I am seeing bad flaking and corrugated surfaces on parts - on the faces of parts matching brightest flare side.
It might be a little “tl;dw”, but I think this video https://www.youtube.com/watch?v=3gWAbKKrR6o illustrates it best - I’m not done yet, there’ll be at least one more video, probably two, but imo this is conclusive evidence of the issues that laser flare can cause.
I call it conclusive proof - because it shows before and after prints - of identical form1 files, with the same vat, same resin (I didn’t even refill the resin, although I did have to strain it) - nothing changed between the prints except that I rotated the laser 180 degs in it’s aluminium block (I am always careful to be wired to earth before touching the laser) .
After rotating the laser - the flaking and surface corrugation switches sides on the parts - ergo - the flaking and surface corrugation can only be caused by the laser flare.
Here’s a pic of the type surface corrugation that I’ve been seeing - NOTE this is not flaking! these parts are washed, the corrugated surface is exactly that - corrugated.
note the right hand side (hinge side) front surfaces. They should be flat. Now contrast with the rear view:
More pictures to come along with more videos - I’m currently running taller versions of the same parts in the new grey resin with a brand new vat - both resin and vat having arrived yesterday.
As @Ante_Vukorepa and @JoshK have already said I think it’s now very clear that the Form1+ laser needs an iris (given that it seems extremely unlikely they would shift to an entirely new laser module). I’m not sure what the solution is though - Josh forwarded me his design but I think it would be difficult to install correctly.
In an ideal world Formlabs would step up - and ship out replacement lasers with pre-installed iris’s (the laser modules are exceedingly easy to install/uninstall) - and if the machine needed any configuration to match a new laser module, it could be done via Preform following an update allowing a remote connection to our Form1+'s.
I’m not holding my breath though - in the meantime I’m working on my own iris design that I hope will be easy enough to install - but I’m certainly not 100% confident on that front.
Thoughts from the usual suspects? any unusual suspects? FL?