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I've figured out what it was, it seems the plastic body of the optical sensor was "loose" and the soldered connections were not holding it in place.
A little bit of glue to lock it in place and it's suddenly super accurate as expected.
If the pcb rattles slightly when you shake it, it's...
I've just upgraded my Voron 2.4 to have a BTT SB2209 RP2040 hotend board with CAN, and at the same time I took the opportunity to switch to an OptoTap.
In hindsight changing two variables at the same time doesn't make troubleshooting easier.
The SB2209 seems to be running perfectly, hotend...
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