Calibration issues / cut accuracy problems

Troubleshooting
1

Hi — looking for some help troubleshooting a Maslow 4.1 setup we’re doing with students.

I’m a long-time Maslow user (older model) and have cut hundreds of parts over the years for our high school robotics team. This year we acquired a Maslow 4.1 and got permission to install floor anchors in the school shop.

Current setup & what we’ve tried

Over the last couple weeks the students assembled the machine, installed anchors, and ran calibration.

  • Firmware at first calibration: 1.15

  • Calibration performed: 9×9 calibration on a 900×1600 area (units as shown in the UI; happy to confirm if needed)

  • Anchor geometry (approx — I’ll confirm exact measurements Tuesday):

    • Top width: ~14’ 0”

    • Bottom width: ~14’ 0.5”

    • Left height: ~10’ 11.5”

    • Right height: ~11’ 0”
      So we’re roughly 0.5” out of square in both directions (student-installed anchors).

Calibration on 1.15 passed. To validate, we cut a test square:

  • File was a : 6" × 6" square

  • Actual (repeatable) cut: about 6" × 5 3/4"

  • We cut once on the left side of a 4×8 sheet, then repeated near the center — same result, so it doesn’t seem location-dependent.

When we checked the maslow.yaml (from the calibration), the values for top X / bottom X / left Y / right Y didn’t seem to match our measured anchor spacing (they kind of close but still off by like 60mm in Y direction and 30 in Y). We manually entered our hand-measured values into maslow.yaml and re-ran the 6" square test cut:

  • Result improved to about 6" × 5 7/8" (still short, but closer)

We then tried small manual tweaks to the X values only (to see if we could “move” that 5 7/8" toward 6"), but eventually hit a center point deviation error and couldn’t recover.

Firmware update issue

We noticed firmware 1.16 was available, so we updated and attempted calibration again. Calibration has now failed repeatedly:

  • Tried calibration 3 times — it keeps failing, on fitness and exhausting the retries

  • On the last attempt we entered our measured anchor values into maslow.yaml before running calibration, but it still failed

We ran out of time for the session, and plan to try again Tuesday.

Questions

  1. With a successful calibration on 1.15, why would we see a repeatable ~1/4" error in the cut dimension (especially since it repeats in different locations on the sheet)?

  2. Any recommendations for getting calibration to complete on 1.16?

  3. What logs/file/measurements/ details should I have the students capture and share here to help diagnose this?

  4. Any other sanity checks / test cuts you’d recommend?

Thanks in advance