@fcwilt
Thank you for your help up until now. I'll continue to do some testing later this week to see if this is motor-related.
I got my Lead Screws from ZYLTech a few years ago. Never thought to look at McMaster. I suspect if there were variations I should see those in my layer lines, which I don't normally have an issue with since upgrading to these. However the anti-backlash nuts are brass and could have some play. I do my best to keep them greased.
ccdbb348-b3b0-4716-a64e-22065dc2e568-20210826_054436 (3).jpg
8748dcee-a21f-499f-90be-87df60da8694-20210829_134923.jpg
I am thinking there may be some play in my Tool Carrier. I know that I can get flex up to 0.14mm when I put some pressure on it, but it does want to return back to 0. Today looking into this further I dove the tool into the bed and found it didn't want to return to its normal height. So I docked and undocked it and picked it up again, the tool height was back to normal. I'm suspecting that it's shifting in the kinematics and even though it's a ball bearing and has no scoring it's not able to return. This would not explain the BLTouch variation, but maybe a factor when it comes to printing.