I was incorrect. I believe the issue in the picture was “overcut” not “lead out”
That is good, I was starting to lose my mind. Not sure why it became an issue now when it never was before, but glad to know what it is. (I think )
Disregard
More details on my ongoing saga in thread below
I am playing with giving lightburn a tiny lenght instead of 0 for the lead in/out, that seams to be mitigating this.