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Hello @Theodore! Here are my observations from your post 1. Your Calibration Chart itself is not looking good. I can see some Air bubbles in the chart! You need to manufacture a very good calibration chart with the perfect planar surface. I have used 5 mm acrylic sheets for this.

  1. Calibration results will also depend upon the number of sampled corner points. So you could increase the checkerboard size. I used 20 x 16 sized checkerboard with 1 cm width. Make sure you capture the images at the center, corners, edges and also at the different scale (close & far). You should also include some tilted images but not in the corners.

  2. You can use Two different Calibration charts one for RGB camera & another one for IR. So that you can calibrate the IR camera more accurately.

  3. Note that you should keep the RMS error within 0.5 otherwise re-calibrate your camera.

  4. For more details refer this useful answer http://stackoverflow.com/questions/12794876/how-to-verify-the-correctness-of-calibration-of-a-webcam

Too long for a comment!

Hello @Theodore! Here are my observations from your post 1. post

  1. Your Calibration Chart itself is not looking good. I can see some Air bubbles in the chart! You need to manufacture a very good calibration chart with the perfect planar surface. I have used 5 mm acrylic sheets for this.

    1. Calibration results will also depend upon the number of sampled corner points. So you could increase the checkerboard size. I used 20 x 16 sized checkerboard with 1 cm width. Make sure you capture the images at the center, corners, edges and also at the different scale (close & far). You should also include some tilted images but not in the corners.

    2. You can use Two different Calibration charts one for RGB camera & another one for IR. So that you can calibrate the IR camera more accurately.

    3. Note that you should keep the RMS error within 0.5 otherwise re-calibrate your camera.

    4. For more details refer this useful answer http://stackoverflow.com/questions/12794876/how-to-verify-the-correctness-of-calibration-of-a-webcam