Cleaned all lenses, cleaned camera, wiped nose, refreshed bed image, did camera alignment print and scan (a week ago).
Here you can see the line is about 1/2 inch out!!!
What can I do to improve accuracy when engraving on small items
I used a caliper for focus depth
It’s very likely the focus laser is missing your item - so @SummersMade’s suggestion of using a caliper to measure and then input the exact height works - or creating a jig that has a hole that your item falls into - so that the entire surface of the jig is the focus height also works. I’d go with the former if you’re doing one - and the latter if you’re doing a lot of the same.
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The message about the caliper was from me 
I did use a caliper.
Even though the focus is set with a caliper the red dot does still happen and does miss the item - so I will work on seeing it I can make a jig as your other suggestion.
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Just out of curiosity, what is your objec sitting on? It doesn’t look like the crumbtray or the GF floor.
It’s a piece on MDF/Draftboard - I included that in the height of the focus.
The ‘switch’ has little pegs coming out of the bottom which means it doesn’t sit straight on the bed.
Ah gotcha. Do try set focus, it also modifies the camera view to be more accurate. Caliper input sets the focal point of the laser itself but doesn’t make for accurate camera view (at least for me). It’ll be a bit tricky on a piece that small. When you invoke it, watch the bed carefully to see where the red dot lands, it wants to be on your object. On my machine, the red dot lands about 1/2" up and left of where I click on the screen.
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I would line it up as close to directly under the lid camera as possible by opening the front door, closing the lid and looking down over the camera to get it just right. Then use your set focus and watch where it is hitting. If it’s off keep moving the set focus until it lands squarely on the piece. Then line up your artwork and go for it.
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I’m so sorry to hear that you’re hit this snag. Based on the material you’re attempting to print on, the red laser dot may be missing the material, and this can cause the alignment to be offset.
Does the same trouble occur if you utilize Set Focus before the print step?
As @deirdrebeth pointing out, creating a jig for these particular prints may also help to improve the results of the print.
Let us know how it goes!
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It’s been a little while since I’ve seen any replies on this thread so I’m going to close it. If you still need help with this please either start a new thread or email support@glowforge.com.