Well I must say that .030" is way too much out of spec for my requirements.
Most of my cutting will be done in area bounded by 3"-4" x 36"-48" and the relationship between the end points must be precise. If I was to only cookie cut areas of 3" x 3" for example, then I would be out of tolerance by about .007 to .008" which is acceptable...barely. However if I was to cut a piece that was 48" in length then I would be out by at least .120" which is way too much.
Secondly, as I'm adjusting the mirrors I am noticing that the focal point of the beam is also moving around...as to be expected. In some cases it does not even make it out of the air assist chamber of which the opening is .125" in diam which is like a barn door in relative terms.
Time to review my measurements and see if I machined anything out of spec.
Mechanically the machine is sound and square...but the alignment of the mirrors is becoming a bit of a concern for this application. During an engraving operation, one isn't as concerned with the final product mating up with another piece. While in cutting, I must be able to cut pieces out precisly so that individual pieces can mate up with other ones without any significant gaps. There are obviously differences between engraving and cutting and yet some similarities as well. I just have to sort out the two in my mind and determine what is acceptable and what is not.
I guess coming from a manufacturing career in high speed automation and robotics, tolerance buildup is paramount in my thought process.
I think I will set the project aside for a couple of days, regroup my thoughts and see where I might have gone wrong or misguided in my design. Only time will tell
Time to crack open a cold one
Richard