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    Laser won't cut despite correct alignment and focus

    I have a Boss LS laser, less than 2-months old, and I am at my wits end with it.

    A little backstory - the machine had a faulty control board that led to the proximity sensor on the auto-focus not triggering and stopping the cutting table from driving the material up into the laser nozzle. I hit the emergency stop, but not before it screwed up the alignment of the table and the vertical alignment of the head. I followed Boss's instructions to realign the vertical and to re-level the table. It is not perfectly level, but all four corners are within ~0.3mm of each other. But since replacing the control board, the machine has needed constant adjustment to keep it cutting, and some days I can't ever seem to get the settings correct. Then, last Tuesday, I turn the machine on and it seems incapable of cutting through a board at all and it has a wider than normal cut, despite the fact that the previous day it was working and cutting fine. I fiddled with it all day Wednesday and get nowhere. And then on Thursday it suddenly cuts again just fine. Then on Friday it was back to fat cuts that won't go all the way through.

    It engraves beautifully, and line work is crisp, but it won't cut for the life of me. I have tried lowering speed, increasing power, doing multiple passes. Nothing. I can put the same 1/8 birch ply into my Glowforge and it cuts beautifully, so I know it is not the material. The focal ideal point seems to shift daily from ~7.2mm to 10mm. I clean the mirror and lens every day - so optics are clean. I went through a total alignment check and everything is spot on with the mirrors. I have attached a photo to see how the engraving is crisp but the cuts are not.

    Boss tech support has been very helpful in trying to solve the problem - but I just feel like I am not getting anywhere. Any suggestions would be greatly appreciated!
    Attached Thumbnails Attached Thumbnails IMG_4502.jpg  

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