VOXL2 Camera Calibration fails and bad QVIO tracking

[kmuenpra]

Drone specification:

I am currently using Starling 2 Max with

• Dual 4k & Dual Tracking & ToF (C29)
• Microhard pMDDL2450 WiFi
• Ghost Atto 2.4GHz
• SKU: MRB-D0012-4-V2-C29-M11-T9-K3 (NOTE: This SKU is from the order receipt, which is different from the one shown when connected to the drone)

system-image: 1.8.06-M0054-14.1a-perf
kernel:       #1 SMP PREEMPT Wed Oct 22 04:13:18 UTC 2025 4.19.125
hw platform:  M0054
mach.var:     1.0.1
SKU:          MRB-D0012-4-V2-C29-T9-M22-X0
voxl-suite:   1.6.3

Cause:

I recently flashed my VOXL2 board by following "Unbricking your VOXL2" page. This wipes all calibration files, of which I generated new ones by calibrating the drone again.

However, I am having issue getting a successful camera calibration with the same error every time:

Re-projection error reported by calibrateCamera: 1.26416
Calibration Failed
Max reprojection error: 0.60
This is most likely due to motion blur, please try again.
Exiting Cleanly

I have tried to debug by following these suggestions below:
https://forum.modalai.com/post/22010
https://forum.modalai.com/post/22066
https://forum.modalai.com/post/21909
However, none of these fixes the max reprojection error.

Finally, I manually write the files:

• /data/modalai/opencv_tracking_front_intrinsics.yml
• /data/modalai/opencv_tracking_down_intrinsics.yml

by using the camera matrix from the trial with smallest reprojection error (close to ~0.6).

Current Issue:

My problem now is that, since the calibration files use bad camera matrices, the qvio tracking of the drone is inaccurate and drifts a lot. Here, I tested the front and downward camera by walking around in circle and returning the drone to the exact starting position. The result shows a lot of drift in both qvio_extended and ov_extended

My questions are:

• Could the reflash have altered camera driver versions, exposure/gain settings, or voxl-camera-server config from factory defaults?
• Is there a way to compare my current per-camera intrinsics files against known-good factory defaults for the M0054 platform?
• Are there other config I should try to change to aid the camera calibration process?
• Is there any other open-source code that allows me to manually calibrate the camera?

Thank you for your time and help!