Recurring 2mm Y-Axis Alignment Shift / Camera Offset Calibration Loop (Creality Falcon A1 Pro)

Creality Ecosystem Creality Falcon
1

Hi everyone,

I am experiencing a highly frustrating and repeatable alignment issue with my Creality Falcon A1 Pro. I have tested this across Falcon Design Space

The Core Symptoms:

  1. The Visual Shift: On the canvas, everything looks perfectly centered on my material preview. However, the physical engraving lands exactly 2mm (approx) too high (upward along the Y-axis).

  2. The “Ghost” Overlay: As soon as the engraving job finishes and the camera refreshes, the digital background image on my screen suddenly shifts upward by 2mm. It suddenly aligns perfectly with the physical mistake on the bed, but the bounding box in the software drops down. It feels like the software is using an incorrect baseline focal/perspective matrix before processing, but updates to reality only after the job completes. Manual coordinate offset changes inside the software are seemingly ignored or overwritten.

What I Have Already Tried:

  • Switched entirely from USB to Wi-Fi connection to rule out communication lag/data drops.

  • Verified that physical Y-axis timing belts and motor pulley grub screws are tight (ruling out a standard mechanical belt slip).

  • Repeatedly re-calibrated the camera wizard and checked material thickness/focus settings. Autofocus works.

  • Always selected material thickness with caliper

  • Calibrated the offset based on the resulting image (but every time is 2mm higher so every time I calibrate 2 mm more) and still doesnt work.

  • Reseted the creality. Updated Design Space, given design space admin privileges

Here you can see the BEFORE I engrave and what happens when I take another picture after I engrave, I do not touch anything other than take the photo.

BEFORE
BEFORE1104×474 49.1 KB
AFTER
AFTER920×413 303 KB

Has anyone encountered this specific 2mm canvas ghosting or a Z-axis limit override loop? Any advice on how to force the camera offset to lock down permanently would be greatly appreciated!

I am desperate.

2

Does this also happen when the piece is located exactly below the camera?
Otherwise it is likely the parallax effect, the height of the object lets the camera see it in a slightly different position than if it was at exactly the same height as the camera was calibrated at (especially if you calibrated it without the honeycomb).

3

I have tried everything.

Data repairing autofocus

Manual autofocus

Full reset

Full camera calibration with Arruco, and with Docs

Full alignment several times

Engrave on paper

Engrave on Basswood

i lineup what I want to engrave and when I engrave I take another picture aand the whole picture shifts off center and what I wanted to engrave no longer matches where its been engraved.

Nothing I can change it, it happens in falcon design and in Lightburn.

The whole machine feels like a paper weight right now, I just cannot make it work. If everything I try to engrave shifts a couple of milimiteres it is impossible to use it