UVtools VS PhotonFileValidator

Does UVTools recognize the files?

As for this, you could try UVTools. I just used it to open an existing ctb file (any will do), remove all layers but one, and then replace that layer with a monochrome image file of my choosing.

If only to rule out some kind of fault with the file itself, if you download UVTools, github here... https://github.com/sn4k3/UVtools/releases ...then you could import your sliced file (the .pwma file) and just check to see if those layers existed.

I do cubes of calibration then cones of calibration as the video above teaches. Then I followed UVTools guide on rest times and z-axis tuning, including using his modded gcode file to slow down the acceleration rates of the z-axis motor https://github.com/sn4k3/UVtools/wiki/Rest-times-and-TSMC. I use this print to test for bloom, layer lines and anti-aliasing performance https://cults3d.com/en/3d-model/various/print-angle-model. Dennys Wang has a good video using it https://youtu.be/cGAgyRVK32g

https://github.com/sn4k3/UVtools/releases/ I think when you install it, and you run a slice with lychee, you get a pop up asking if you want to check with UVTools. Otherwise, just open UVTools, drag the .cyber file on to it, and it will Analyse it. You can then look through each layer.

I think 2.5s exposure looks about right. You could try printing tests in 2.3-2.7 range to fine tune it, but I think it looks okay. Try printing updated Towns and cones to troubleshoot other settings. I do recommend reading this about raft heights and bottom exposure times. This article is also a good read to find out about wait times and how to use UVTools to adjust some parameters that Chitubox can't.

I would dial down your lift speed. I personally follow the advice of people like Ameralabs and don’t use TSMC. To me it looks like the model is pulling away from the supports when your fast lift speed kicks in because it’s still attached to the FEP. If your Saturn 2 is anything like my S8K, acceleration is also probably coded high from the factory. I followed this advice https://github.com/sn4k3/UVtools/wiki/Rest-times-and-TSMC I’ve only been running test prints to improve my print quality, and haven’t printed anything as big as you are printing yet, but the reasoning is sound.

This happens to me when my model has some island between the support and the model. Usually I use a program, Photon File Validator, to verify my model after the slicing processing. The program is free. https://github.com/Photonsters/PhotonFileValidator

I will definitely second Chitubox as well, just as many folks use and recommend Lychee as Chitubox, so try both and pick your preference. Chitubox does now have island detection, though I would recommend Photon File Validator for more complex prints where you really want to be sure you've caught everything. It detects and indexes islands quite nicely and has a function to 'fix' (read: fill) single pixel gaps causing islands, though those aren't a big deal anyhow. Only downside is having to export as a .cbddlp from Chitubox, import into the validator, then reimport the fixed file into Chitubox for any additional manual supports.

You'll have to forgive me, but I need a little more detail to help. Let's take the Photon File Validator.

To double check for islands you can use Chitubox v1.8.0 and above. Or download Photon File Validator, Whilst chutibox can repair files, it is not particularly good at it, but it will highlight problem areas that you might be able to fix with additional supports. PFV on the other hand cannot add supports, but allows you to edit the pixels on each layer.

Check your sliced file in something like UVTools or the photon file validator to make sure it isn't a slicing/file transfer error (unlikely but worth a check).

.photon lets you use the Photon File Validator, but for .pws you can still use alternatives like UVTools. UVTools can also be used for converting sliced files between formats.

Double check the sliced file to make sure it isn't a slicing issue. A quick check in something like PFV or UVTools will tell you.

I'm assuming an original Photon, and you've had it a while. If the sliced file looks ok when scanning through the layers (Either in the slicer or PFV/UVTools), its either printer settings or a hardware issue.

I orientate pieces manually, just eyeballing to try and minimise areas that'll need excessive supports. It always seems to work out for me. I still run my sliced files through PFV or UVTools to make sure it hasn't missed anything major, and its never let me down. When removing the supports combined with warming the part, the supports come off beautifully and leave almost no trace, its like magic! But I think thats less PrusaSlicer, and just good practice in general.