[Algirdas]

1. First of all. If you ever tested with no cutting load? Axis movement "in the air" ?
2. Split the points to check:
- Power supply. If there are no voltage drops below acceptable level?
- cooling. Driver chips produce heat. Use heat sink and fan to cool down.
- control issues. Try different approach. Check if control signal is reaching the final point ( the motor ) correct way.
- timing. Check if mistakes multiply with speed increase. Maybe is possible reduce mistakes by just taking lower speed.
3. Conception of controls. You can follow the jig error using encoders.

[sparrowlegs]

1. First of all. If you ever tested with no cutting load? Axis movement "in the air" ?

Yes, so at 800p/r I can happily rock at 4000mm/min, no problems with the driver overheating/shutting down. However at 400p/r, the drivers overheat around 5min mark @ 1000mm/min. No load.

2. Split the points to check:
- Power supply. If there are no voltage drops below acceptable level?
- cooling. Driver chips produce heat. Use heat sink and fan to cool down.
- control issues. Try different approach. Check if control signal is reaching the final point ( the motor ) correct way.
- timing. Check if mistakes multiply with speed increase. Maybe is possible reduce mistakes by just taking lower speed.

Not fully check voltage drop, its on my list.
Cooling, as I mentioned about, since running a 120mm fan, that this has helped me run at 800r/p @ 2500mm/min cutting
Control signal, well this must be fine as the motors are working.
No matter what speed I run at 400, though the moment is smooth, the drivers get way to hot. I may investigate if reducing the acceleration helps. Also got to check if the clock speed on Mach side is correct, though again, 800 required a higher clock speed that 400.

3. Conception of controls. You can follow the jig error using encoders.

As mach3 doesn't read encoder feedback and the TB6600 doesn't have this capability, this isn't an option. Agreed if I upgrade to a hybrid driver like Leadshine then this would be a useful. (Though I suspect I wouldn't have any issues in the first place which such premium drivers.)