So Affinity Designer is interpreting the image as 300 DPI. Looks like LightBurn is interpreting it as 144 DPI (at least on my system). Oddly, I’ve checked the file with a couple of different methods and one shows it as 72 DPI, and the other as 144 DPI.
I suspect the file itself is either ambiguously or improperly defined.
But it seems there are multiple things going on in your particular case:
Somehow your LightBurn is interpreting things consistently at 72 DPI
The files you’re working with may have an issue with header definition
I’m not sure what could affect the first scenario. I haven’t seen that. It’s odd.
For the second, you may want to check a few other mechanisms to generate the files to see if you get a different outcome.
This video explains a lot about using Affinity Designer. Near the end (around the 30 min. mark) it goes into the correct settings for exporting your file for use with your laser. This may have something to do with the scaling issue. https://www.youtube.com/watch?v=bYhY2sBTNjQ
Affinity has a “project level” DPI setting that I believe it uses for everything, so it’s quite possible that when you save, it’s saving the images with that DPI setting, not whatever the original was.
LightBurn reads the DPI value from the source file, and imports accordingly. If you save an image from PhotoShop, CorelPaint, Paint dot Net, or any other software that properly writes the DPI values into the file, it will import properly in LightBurn.
I just reimported and it’s showing 3.9367 inch square. I designed in inkscape at 4 inches and exported to PNG at 300 DPI. Installed paint.net to compare and also shows up as 3.94 inch square. So all apps in my world are consistent.
It’s entirely possible that the version posted to the forum was altered by the forum software. Sometimes these systems will re-compress images for space. Regardless, your source version is consistent across all the apps including LightBurn, so that’s really what counts here.