I'm posting his observations to see if anyone can help out. Here is what he observes:
Any ideas on this issue are gratefully appreciated. thanks !But the new(ish) problem is that the laser is really doing some odd things with short lines. Instead of just firing like normal, it draws a dot, pauses to think, tries to draw the line but just makes a 3rd dot in the middle, then draws a dot at the end, pauses, then fires at a power level well over what it was set for, then moves on to the next line. So instead of a short 2mm line you'll get a dot, a very weak line or a dot, then a a very very strong dot. Its as if the controller is pausing for a moment between lines, and decides to just keep the laser firing while it thinks.
Speed was at 99. Problem is any lower and the laser just burns right through the paper. I'm not sure it's a speed issue though because I was also doing some through-cuts at speed 50 and on some intricate shapes it was doing the same thing, pausing at corners for a half second or so and burning a big dot.
It also doesn't do it with every line, sometimes you'll have like 50 identical lines with identical spacing in a row, it will then over-burn every 5th or 3rd or 10th line, but it will be consistent in that respect and create a pattern.
I made a little video. You can see it stops to "think" every 2nd or 3rd line. It should be rapid-firing these lines out without pause. They are 2mm lines. I have a similar pattern of 4mm lines that it does very quickly without these pauses. It seems to only happen with lines under 3mm or so.
https://youtu.be/UkAFTgaFTkk
You can hear the power supply or laser click a few times while it thinks too, each click sends a blast through the laser resulting in the nasty holes.
Mike