Hi Mark,
I've been following a similar path, but with the Xerox/Tektronix Phaser solid wax ink printers.
I have a 8400 and an 850D that I run 8mil thick flexible single sided stock in the manual feed path.
It works well to a point, except sometimes I have to preheat the board going in.
It's been hit and miss as I think I've been running into electrostatic issues similar to what you've
been working through.
I'm going to try the Carbomer/alcohol/water shared by David
yahoo@... (www.laserpcb.com),
1 cup water, 1 cup isopropyl alchohol, 4 tablespoons Carbomer 940
To see if that helps bring the line resolution down.
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∗∗∗Your toner method has really good advantages that are leading me to abandon the solid wax printers:
1) Your line resolution looks better.
2) If the transfer has issues, your method is much easier to dust off clean and redo. I have to strip the wax off & re-clean.
I have a E260DN ready to do your modifications( You do very impressive-creative work, process, and docs!! )
-Bought a small lab supply 0-10kv for experimenting just in case.
Questions:
1)I had a question about your instruction/comment below:
"Interestingly, using an un-coated aluminum carrier will not work
it seems to require much less transfer voltage!"
Sorry if I sound dense, but does this mean "the coated carrier makes it require much less transfer voltage"
2) It seems as if the carrier and the PCB with the help of the KY make a simple capacitor
between the carrier's( expoxy insulated) inner plate
and the PCB surface. I was wondering if some of the
KY is conductive somewhat, and is it touching/bridging to the PCB surface
copper. Just curious on what you think?
Thanks,
-Lee