Okay, so… i’ve been trying to print something i’ve already printed fine once (at 0.2mm layer height the first time, at 0.1mm during the latest attempts) in Clear and keep hitting the same wall over and over again.
The part keeps accumulating these large flaps of semi-cured resin on one side. I can’t even call them “flakes” as they’re huge. Eventually, they end up stuck on the bottom of the tank and the print fails, usually near the very end. Now, the fun part is - the flaps are not delaminated parts of the print itself. And they’re way bigger than the usual flakes due to flare.
I’ve recorded a vid to illustrate the consistency of the flaps:
If it weren’t for the damage to surface quality caused by the flaps and removal of flaps, and if they didn’t eventually fail due to accumulation of same flap material on the bottom of the tank, the prints would be fairly successful.
Interesting factoid - the flakes don’t merely accumulate as the print progresses - they start all the way down, near the base. Changing the orientation changes the side most affected - the greatest accumulation is always on the hinge side, from what i can see. I’ve checked the mirror and it’s clean. I blew off, then wiped the dust with a pec-pad just to be on the safe side (even though no amount of dust could cause even curing of flap-like blobs like that).
After the latest failure, i’ve checked the rear mirror (more thoroughly for the first time) and noticed it seems pretty speckly. It also appears to show reddish-hued shifts in surface quality at the very bottom (looks like some kind of an artifact in the silvering) and two very fine, thin “scratches” that aren’t truly scratches, but again, look like a slight defect in the silvering (they’re red and don’t look like they’re on the surface). Both artifacts are at the very bottom, where they couldn’t affect the beam, from what i can tell. Besides, considering i’ve never touched the small mirror, i’m pretty sure those were there from the beginning.
While debugging, i took a look at the laser spot without the cover on (for the first time) and noticed there’s quite a huge halo around it (that’s not normally visible through the cover). How usual an occurrence is this for Form1+? The halo is composed of tiny dots, which to me indicates it’s an artifact of diffraction and probably caused by something very near the laser optics.
I’ve also noticed the laser pattern has a tiny, sharp (higher intensity) line jutting out to the left side (towards the hinge). I’m not sure i’ve noticed that the first time around. I did post some spot photos here on the forum, but can’t seem to find them at the moment.