Troubleshooting Inconsistent Engraving Depth on the Ray5 20W

Inconsistent engraving — some areas deeper, some lighter, or depth varying across the bed — has several causes. Here's how to diagnose and fix each.

Common Symptoms

• Engraving darker on one side of the bed than the other
• Depth varies across a single design
• Correct settings one session, too light/dark the next
• Horizontal banding (lines of alternating depth)

Cause 1 — Uneven Material Surface

Test: Lay a ruler across the material. Is there any bow or warp?

Fix:

• Clamp/tape material flat before engraving
• Add weight to warped areas
• MDF can absorb moisture and bow — let acclimate to shop

Cause 2 — Incorrect or Inconsistent Focus

Test: Run a focus ramp test — is sharpest focus consistently in one position?

Fix:

• Re-calibrate focal height
• Ensure laser head clamp is tight (loose head = variable height)
• Check for debris under material raising one side

Cause 3 — Dirty or Damaged Lens

Test: Inspect lens with a loupe or strong magnification.

Fix:

• Clean with IPA on lens-cleaning swab
• Replace if scratched or pitted (Ray5 uses common lens size)

Cause 4 — Horizontal Banding

Regular horizontal bands at consistent spacing = mechanical issue.

Causes:

• Y-axis belt tension uneven
• V-wheels worn or not seated
• Frame not square

Fix: Check belt tension, adjust V-wheels, re-square frame

Cause 5 — Power Supply Sag

Engraving lighter toward end of long jobs = power supply struggling.

Fix:

• Run on dedicated outlet (not shared with other equipment)
• Check laser power setting isn't near max for extended periods (use 80% max for long jobs)

Cause 6 — Speed Acceleration

On direction changes at high speed, the laser dwells slightly longer = darker areas at edges.

Fix: Enable Overscan in LightBurn (2–5%) — extends travel beyond the design area before turning.