Can anyone enlighten me as to why I’m not seeing smooth movement in this…rapid speed set to 500mm/s proportional feed rate set to 400mm/s Light and 350mm/s dark. But at times the laser head is only traveling at what I would guess is 10-50mm/s…
Can’t help, but interested to know too.
Yes I suspect that this is a highly segmented gcode file? ie lots of tiny segments? If so then there are two possible reasons (maybe both) 1. it can’t send the gcode fast enough 2. the planner buffer is filling up with tiny segments and so cannot reach full acceleration as there is not enough room in the buffer to combine a length of tiny segments that is long enough to reach full speed.
@Wolfmanjm would there be a possibility that I would have better luck playing the gcode file directly from the SD card?
It will help a bit but you have to understand that if the gcode line executes faster than it can be read or received and planned then the buffer can never fill up which means it can never be planned ahead which is what allows lots of small segments to be combined and reach full acceleration. If you can post the gcode file somewhere for me to look at I can see which of the problems you are running into. (I suspect it is both).
Looking at the gcode I suspect it is simply filling up the planner queue with short segments so it can never get up to full speed. it may be slightly faster from sdcard but I doubt it.
I did notice windows defaulted my baud rate to 9600 on the com port… I changed to 115200 and saw a slight improvement … I was also originally running from a tablet PC and switched to my more powerful Laptop and saw a performance increase as well
baud rate is totally ignored for USB serial devices, if you are plugged into the smoothie USB port. USB serial runs as fast as the USB lets it. There is no baud rate per se.
The way the new stuff wokrs is it fills up the planner queue before it starts actually running, so long as the serial can keep it filled it will plan. However there are only 32 gcodes in the queue and if those 32 do not add up to a length long enough for the acceleration to allow it to reach full speed it will only get to a fraction of the requested speed.
@Wolfmanjm I noticed in the Smoothie config there is an option to change the queue size. Is it possible or even wise to increase the queue size?
you can try to increase it to 64 but it may crash as it could well run out of memory. You will need to strip your config to the bare minimum and exclude networking and any modules you are not using. But if it works then it would be interesting to see how much (if any) it improves things
Will test tomorrow night 
thanks @Wolfmanjm please post a link to your Beer fund so we can spread the love for all you have done to help
@Wolfmanjm does it need to be a binary increase of lines? So 64 would be the next set of bits or can I choose a number between 32 and 64
yes must be binary 16. 32, 64
Hopefully it can make a difference on @Alex_Krause 's speeds. I’d be interested in seeing the results of a change (for my future reference).
there is a donate button on the wiki… http://smoothieware.org/
@Wolfmanjm did you get an answer too this as I seem to have the same issue?