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Ran into a very bizarre issue today that I haven't seen before. (I'm not even sure what to Google for more information)

There are just visible plateaus of resin. The bottom of the model at one point simply didn't print or separated?

Resin: Anycubic Green

Things I've tried so far:
• Different exposure settings.
• Different USB sticks.
• Putting the file through an STL repair.

Other oddities:
• I've printed this model before from this exact file.
• Other models print fine.
• Started happening after replacing FEP.
• After replacing FEP, this model wouldn't print with regular exposure, had to up it from 10s to 12s or it would leave a single layer of hardened resin on the bed.
• Printer is not near UV light sources.
• Temperature is moderately controlled.

翻譯年糕

What am I doing wrong here?

Sometimes if I reprint it will just work with no changes, other times it'll keep happening again and again.

翻譯年糕

Just had to replace the FEP for the first time. Used a 13mm~ bottle cap, makes a nice drum noise when lightly tapped.

The only "issue" now is I hear a subtle popping noise every time a layer lifts from the film. Is this normal?

翻譯年糕