I'm far, far from an expert on the software/firmware so this is just me thinking out loud. I believe daid (the creator of cura) mentioned a little while back that he had increased the resolution of the output in the latest version. Could it be that the Arduino is now being taxed too hard due to the increase in moves it has to plan and execute and not able to quite keep up, thus causing "micro stuttering"?
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I'm not sure if it helps, but:
Have you ever tried while printing the "material flow" directly on the machine in "TUNE" to adjust?
I know this is not the right way to permanently solve problems. But it would be very interested if you so will achieve a visible improvement.
And the problem is certainly not the material currently used, or other mechanical problems?
Markus
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