Redline / J-tech Laser Issue (Solved, Post processor issue)

RealTime Controller (RTCNC) Bugs
1

I recently upgraded from my original Buildbotics Journeyman, which I had for several years, to the Gen2 Foreman w/ Redline controller. I am trying to set up and use my laser for the first time, and I am having problems.

The issue I have is that when I attempt to fill engrave, I get deeper engraving at the start and the end of the burn, but lighter in the middle, much like a dome effect. It doesn’t matter what the hatch angle is either.

Although it is a cool effect, it isn’t what I need.

This is the same laser I have been using since they introduced it a couple of years ago, and it worked flawlessly on the Buildbotics system, with hundreds of files successfully completed.

I have downloaded and updated the newest post processors from Vectric as well as the post processors from J-Tech. In addition, I have tried various levels of overscanning, and nothing corrects this issue. The G-code looks good, and I have searched both the net and the forum, with no success. It doesn’t appear to be a Vectric issue, as the G-Code looks similar to other files I have run successfully on the BB controller.

I have attached the G-Code as well as an image of the test file.

I currently have an email out to Onefinity, but I thought I would reach out here as well.

  • Gen 2 Foreman
  • Redline Controller
  • Redline 80mm 1.5 KW Spindle
  • J-Tech 64w Laser (operated at 24w for this test)
  • Vectric Aspire 12.510
  • Realtime RTSX Post-Processor, obtained through Vectric today.

20260809_192713
20260809_1927131920×1081 823 KB

First several lines of the GCode for the sample image

%
(VECTRIC POST REVISION)
(3FDECA1D9BFA3FE0DB77321B69E40BFA)
(Onefinity Realtime RTSX (inch))
G17 G20 G90
G53G0Z0
G0X0.00000Y0.00000
T1
M6
G0X0.50762Y0.34093
G0Z0.25000
G0Z0.20000
G1Z0.00000F200.0
M3S0
M3S650
G1X0.52530
G1X0.53512
G1X0.52530
G1X0.50762
M5
G0Z0.25000
G0X0.51887
G0Z0.20000
G1Z0.00000F200.0
M3S0
M3S650
G1X0.51869Y0.35620
G1Y0.37361
G1X0.51878Y0.41495
G1X0.51887Y0.46504
G1X0.51878Y0.41495
G1X0.51869Y0.37361
G1Y0.35620
G1X0.51887Y0.34093
M5
G0Z0.25000
G0X0.60726Y0.36790
G0Z0.20000
G1Z0.00000F200.0
M3S0
M3S650
G1X0.61034Y0.35988
G1X0.61458Y0.35299
G1X0.61998Y0.34732
G1X0.62655Y0.34299
G1X0.63422Y0.34024
G1X0.64297Y0.33933
G1X0.64872Y0.33967
G1X0.65436Y0.34069
G1X0.65988Y0.34239
G1X0.66530Y0.34477
G1X0.67035Y0.34776
G1X0.67480Y0.35127
G1X0.67865Y0.35530
G1X0.68190Y0.35986
G1X0.67865Y0.35530
G1X0.67480Y0.35127
G1X0.67035Y0.34776
G1X0.66530Y0.34477
G1X0.65988Y0.34239
G1X0.65436Y0.34069
G1X0.64872Y0.33967
G1X0.64297Y0.33933
G1X0.63422Y0.34024
G1X0.62655Y0.34299
G1X0.61998Y0.34732
G1X0.61458Y0.35299
G1X0.61034Y0.35988
G1X0.60726Y0.36790
G1X0.60538Y0.37678
G1X0.60476Y0.38629
G1X0.60534Y0.39544
G1X0.60708Y0.40433
G1X0.61003Y0.41256
G1X0.61422Y0.41977
G1X0.61967Y0.42580
G1X0.62637Y0.43049
G1X0.63021Y0.43224
G1X0.63440Y0.43350
G1X0.64387Y0.43450
G1X0.65277Y0.43359
G1X0.66056Y0.43084
G1X0.66726Y0.42658
G1X0.67288Y0.42111
G1X0.67739Y0.41457
G1X0.68074Y0.40709
G1X0.68295Y0.39899
G1X0.68405Y0.39057
G1X0.60530
G1X0.68405
G1X0.68295Y0.39899
G1X0.68074Y0.40709
G1X0.67739Y0.41457
G1X0.67288Y0.42111
G1X0.66726Y0.42658
G1X0.66056Y0.43084
G1X0.65277Y0.43359
G1X0.64387Y0.43450
G1X0.63440Y0.43350
G1X0.63021Y0.43224
G1X0.62637Y0.43049
G1X0.61967Y0.42580
G1X0.61422Y0.41977
G1X0.61003Y0.41256
G1X0.60708Y0.40433
G1X0.60534Y0.39544
G1X0.60476Y0.38629
G1X0.60538Y0.37678
G1X0.60726Y0.36790
M5

2

By looking at your picture, my first thought was it looks like you have ZERO overscan, but you mentioned you have adjusted that at various levels. Do you actually see the machine physically going past your vector when you have a large overscan set? My second thought is, do you have Outline configured on your toolpath? It looks like the Outline option is causing the deeper/darker burn at the edge of your circle.

Sorry I can’t be of more help.

3

Now that I’ve looked at your picture in more detail… I see what you mean. It’s almost like your X rail(s) are bowed upwards in the middle, causing the laser to go out of focus in the middle of the burn. Is this a whole new Gen 2 machine with new rails? Or did you upgrade your original Journeyman system to the Redline controller?

When you adjust the hatch angle, does the “dome” rotate and match the hatch angle?

4

Roger, Thanks for the reply. When I was using the overscan, they did physically move past the engraved area. I am also not using the Outline option. The angle does not matter. I rotated it to 90 degrees, and the burn was deeper at the top and the bottom, but light in the middle. .0545 deep on the starting and ending edges and .0120 in the middle. The z-height does not physically change during engraving, so it must be a power change or a slight speed change that is not visible to the eye. This is a brand-new machine, but I’m using my existing J-Tech Laser. It all worked flawlessly on my old Buildbotics machine. Onefinity responded and wanted me to download Lightburn and create a test file to see if it is a Vectric issue. I am trying to learn how to do that in Lightburn now…

5

Gotcha. Yeah… this is such an interesting issue. I assume you’re never seeing a power change, from the 65% configured in your toolpath, anywhere throughout the entirety of the Gcode?

It will be very interesting to see if you experience the same issue with gcode created via Lightburn. But honestly, if you never see a power change (from the 65%) anywhere in the Vetric created gcode, then it has to either be a speed issue like you said or some strange issue with the laser itself. Could it be one (or some #) of the individual 12 lasers in your laser is cutting out? But how and why to cut out and then turn back on on each line/pass…? Strange. I’d definitely give a call to Jtech as well. A real person in Texas answers the phone and they will work with you right then and there on the phone. They have always been very helpful to me when I’ve called. (281) 549-6199

Please definitely share what you figure out on this thread.

6

A couple of thoughts for you:

If you download the Lightburn demo, you’ll find several built-in test files under “Laser Tools” that are quite useful.

Are you aware of the max/min power settings in Lightburn? They are there to reduce power as the laser slows down or accelerates at an end of a scan, and should be different values. That would be an interesting experiment.

I was skeptical of Lightburn’s utility at first, but after a few test runs, I bought it. It’s a great value for $100.00.

7

Thanks, Michael,

I’ll take a look at that to try to troubleshoot it. I downloaded Lightburn and created a similar test project to the one that I made in Aspire, and I received the same result. I know that Lightburn is more powerful and has a lot of options; however, my main concern is that I regularly create projects that combine both laser engraving and CNC engraving. Having to use 2 programs to accomplish this because of a software issue makes it much more difficult to take a project from concept to a finished project. This is one area that my old Onefinity with the Buildbotics controller excelled in. At this point, I wish I had never upgraded.

8

It’s a pretty steep learning curve, I know. Experience will make it easier. One thing I did that helped a lot- I created macros to offset and de-offset(?) the spindle vs the laser. Another set of macros fires and stops the laser, so I verify my zero points.

I’ve permanently attached my JTech laser to its mounting plate, so switching over is just a matter or quickly running in 4 bolts.

Another help is to mount your laser so it’s about 1/2" lower than the spindle, with the bit and collet removed. That makes switching relatively painless.

The tough part for me is remembering to switch from laser to spindle in the HMI.

9

@Thomasaburt Hi Thomas, was just wondering if you’ve made any progress on this very interesting issue?

10

As I mentioned earlier, I reached out to Onefinity and, after a couple of email exchanges, they suggested I contact J-Tech directly, as their only solution was to use Lightburn instead of Vectric. This wouldn’t work for me, as many of the projects I create combine laser engraving with spindle engraving/cutting.

Here is a better cross-section photo of the issue. The burn is much deeper at the beginning and end of the laser head movement.

Cross section of the problem
Cross section of the problem1920×1081 274 KB

I initially spoke to Shane, and he felt that it was probably a post-processor issue.

Later that night, I emailed J-Tech images of the issue, my settings, and the G-code Aspire produced using the Onefinity Realtime STSX post processor bundled with the Vectric database.

I received a response directly from Jay after he reviewed everything, and he indicated that the Onefinity Realtime STSX post processor was the source of the error and that I should try the Redline post-processor he attached to the email, as well as using the overscan function. Once I made that change, I was able to successfully complete a project. I have pasted his email text as well as the post-processor and images of the issue and suceesfuul post-change test.. The only thing I need to remember is that this post-processor does not have any Z control, so I have to make sure it is zeroed out before I start firing.

Jay to the rescue!

Jay’s answer

"Hi Thomas,

Thanks for your email. Yes, the laser should not stop at every change in power control like you are seeing. I looked at the G-code file and noticed that using the Onefinity Realtime STSX post processor outputs an “M3” to turn the laser on and a “M5” to turn it off. The M5 command basically tells the controller that you are turning off your spindle, so the machine needs to stop. This is causing the issues.

While you can use the M3 command, you should pair it with only the S command to change the laser power afterward. You can use the “S0” command to tell the controller we want the laser off without stopping instead of using the M5 command.

I would be interested in seeing what you get when you use our Post Processor. We use the M4 command for the laser, which allows the motion to continue. You can see the post processors here on our site:

The Redline inch version V4 is here: https://jtechphotonics.com//Downloads/PostP/LaserModule/Redline_Laser_No_Z_in_V4.pp

Best Regards,
Jay"

Redline_Laser_No_Z_in_V4.pp (4.6 KB)

Successful engraving done on cherry using the 24-watt laser, 50 power, 100 ipm, 50% Overscan, and .006 stepover

Succesful engraving with JTech PP
Succesful engraving with JTech PP1920×1081 803 KB

11

Glad you got it resolved and thanks for sharing the update. Very much appreciated!