Cool, sounds like you’re making some good progress in understanding the problem and narrowing down how to fix it.
I have been running Orca V2.1.0-beta for a few weeks now and haven’t had any issues if you want to try that version. I wanted the Multi-device option but I think it includes other Bambu Studios updates as well. OrcaSlicer 2.1.0 Beta released – All About Bambu
For your 3 differences:
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Are the 2 purge lines just an issue because they aren’t sticking? The mini’s only print 1 line but the A1 prints 2 lines and they don’t cause any problems for me.
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I have the textured plate offset in my Orcaslicer Machine start G-code. I set mine to -0.022 because I wanted to drop the nozzle a little but I think you should have the same but -.02 instead. Maybe try to copy and paste into notepad to see if you can find it.
This is in Printer Settings → Machine G-Code → start G-code.
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I rarely watch my print leveling anymore but I think that is handled by the printer firmware, not the slicer? I’m definitely not sure and a quick forum search didn’t fully answer it but some people are talking about it here Auto bed leveling pattern?
I have a smooth plate and was having some issues with PLA prints sticking to it so switched back to the textured and haven’t looked back.
Any progress in the past few days?