2 inches is not remotely acceptable, and no, re-alignment is not required between prints. Once the camera calibration is successfully completed, it shouldn’t have to be done again. Did you use the set focus tool and get this misalignment? That would really be a problem.
Okay, yeah something is out of whack. It should look like the first one not be off by that far. Did the head hit anything? No debris on the tracks? Didn’t move it by hand while the machine was on or bump it?
Try turning off the machine then turning it back on and see if it still does it.
Does that mean you cleaned it with the machine on? If the head is moved at all (without a motion plan), it will not know where the head is at. So if you slid the head over a bit to be able to access the lens or whatever, it will effectively have lost it’s known position.
When you say two inches, was that from the overlay to where it actually printed? There had been confusion lately (and always) about how the bed image is cropped; that the left side and top side are cropped, so you can’t see the full sheet of material.
I’m sorry you ran into trouble with your print alignment. I’m glad to hear that your most recent prints have turned out as expected. That’s great! Would you please let me know if you’re still having trouble the next time you try a print?
If you adjust your view based on the camera after opening the lid and without doing a new set focus it will skew because the camera has been moved.
If you just hit print it should be in the same place on your board. If it’s not, then you’re managing to bump the laser head/arm while opening cleaning