My first thought was that an i3 would not have enough grunt for this type of work ( just my thoughts...no proof )
Check the PC's performance under Task Manager while doing a job...see if the CPU or RAM are Maxing out. Other trends may give you clue as well....
More RAM *may* help if you don't have enough,( Probablly need at least 4 Gig ...more better) OR your CPU still still NOT be up to it...hard to say....
. 'Never has an issue' with running Mach 3 or just generally?
Some feel the USB system on Laptops are not robust enough for this sort of work. I have NEVER used a Laptop....others have no problems at all using Laptops......
Do you have Desktop PC you can test with?
Overheating *can* cause this....also bad RAM, and other reasons....lol
Is the USB cable screened? Cable needs to be 'good quality'....more important than being new.
Electrical noise generated by poor wiring in your control box may be the source of all your problems.....The trouble is you will void the warrenty if you open the box to have a look...some say your not loosing anything....lol Your call.
Basically, everything should be earthed to the same point.
Good luck.