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If it's something it's only the Optimizer printhead. There is actually a test for it in the printer. Image quality menu, top corner "..." and then "optimizer depletion test" or similar.

How much use on the printhead? The cartridge is unlikely cuplrit. Rather replace the printhead if you want to try.

Post some pictures. I'm not 100% sure what you mean but I think possibly your optimizer PH is bad.

Have you tried to follow the user guide section 3.5.3 Mirror reflective media and OPOSCAM ? Also if you are on the new Onyx V24 it now has automatic white overlay for the marks to help the cutter read (say if you happen to use black vinyl ex.).

I've been using our machine now for some time and so far so good. No issues, no errors at all. Printing great. I can probably answer a lot of questions if someone wants to know something.

Sometimes it pays to contact HP before throwing parts. They know this first hand anyway, only let it out a week ago.

Eh that's not normal by any means. Your unit has a real issue you should get checked out.

It's not always true. Drag knife is faster in some cases because it doesn't lift up. Might make a huge difference if you run a lot of those jobs. Someone would pay huge money to cut 2-5x faster. Just the right tool can do it.

That HP cutter is Summa S One. There's almost no difference at all, same factory, same model just tiny firmware differences. Unless you get the HP branded one a lot cheaper you might as well get Summa. It's basically the same as your D160 with new design. But if you want an upgrade, get the S3...

I think there's a bearing and a magnet inside. But I haven't tore one down. And also I checked in Summa docs "Drag module is NOT a repairable part". So they won't repair it.

It has the drag head inside. It always defaults in "up" position so it's not like the spring is pulled all the time. Now I was thinking but I don't remember what head it has exactly. D and S head is different design.

Yes. It's nothing else than a cutting head at the bottom.

Have you been using it long? I think Summa specifies it as "consumable" basically with certain life expectancy and then you buy a new one (in case it fails). They don't even recommend to service it if you have problems.

What's the up-height set to in axis control? You probably want to max it out.

I know it won't help OP but at least the new one is a lot beefier.

That's pretty important. Means you have issue with the sensor. Check it and the cable, replace if you can't find anything.

What are the error messages??

I don't know what to compare. Moving the gear that moves the cloth sort of feels like starting a lighter. Some tension because the cloth has a break but nothing crazy. Anyway when everything is normal you wont get any build up. It will move fast enough to barely get any.

No and I think you are asking the wrong question. I would tackle this: Is your maintenance cartridge faulty? Rack engage motor faulty? Printhead or something leaking into it? If you have ink in the cap then your printhead is faulty.

Now that's great, I see it was my 2nd guess. Thats the thing with these. Error is just a clue and you must figure it out. Sometimes it's easier.