We are having a lot of issues with delamination/detachment mid print. The parts adhere perfectly fine to the buildplate, but after printing a few millimeters the prints stop adhering to the base of the parts. It is not a singular issue with a single part/section detaching, it happens on all parts/sections across the buildplate at the same time. When printing ~20 different parts, they all fail at the exact same height. And it is not detaching at thin sections, it it can be in the middle of very substantial parts or in the middle of printing the “Full Rafts”. It appears almost like the printer skips or miscalculates the Z height and just start printing in the middle of nothing. There are never any partially attached layers remaining. It is a clean even detachment across the buildplate.
We have had the issue happen 5+ times now when printing with Durable, but not with other resins. Though we have used Durable the most recently, so could be a coincidence that no other resins have failed. We have replaced the tank 3 times. When it fails during printing very large/many parts, it fills the tank with a several millimeter thick layer of cured resin that is hard to remove without damaging the foil etc. During fails with smaller parts we have filtered/strained the resin and cleaned the tank.
It is getting rather expensive to repeatedly replacing the tank, not to mention the loss to productivity. What could be wrong? Anything we can do to prevent this issue?