Unfortunately, I’m still getting errors in the console and the laser still stops, although it seems to happen less often now. 
Do you have any other loads plugged into that circuit?
It’s plugged into a power strip, and as for the USB connection, it’s the only device connected to the computer
Damn!!! It is an indication that there are bad contacts or interference (noise) in the communication. And I really don’t know how to help anymore after everything that has already been suggested… 
There are so many possibilities that can cause this issue…
Did you try grounding the laser unit as Tim suggested.
I see the S6 has an exposed circuit board so could it be vulnerable to static or static cling and could that cause a buildup of dust in hard to see places. Could you try a can of compressed air to blow out dust from around components.
How much %age wise was the improvement after fitting new cable with cores.
After the new cable and its connection, where is the next vulnerable link in the chain.
What type of surface is the machine on, could it promote static.
As for the issue, during a 2 hour engraving, I only had 2 errors, which is much less than usual, definitely an improvement.
The laser is placed on a wooden table.
I haven’t grounded the unit yet, I was planning to do it this weekend when I have more time.
However, I’ve been trying to figure out exactly how to ground it, since the power supply is DC and only has a + and – output.
Does this wiring method seem correct and safe? It’s what I’ve seen in a few videos, but I’d like to be sure it’s functional before trying anything. 
(The red crosses are for fixing the earth cable, and the green cable is for the ground connection.)
Far be it from me to speak on electrical issues, but I was more thinking of static charge of the kind that builds up where you have around moving parts and power sources..maybe like a field.
I was thinking more along the line of earthing that general static buildup by means of a copper wire to earth.
It is often mentioned here on the forum and when I looked it up EMI and RFI, issues are dealt with in many situations using various types of shielding and charge pickup strips of copper etc. As a search for such products will show
As you have had some sucess with the new cable and cores..Great news btw, perhaps a line of earthing wire atached to the frame and gantry (folowing the same line as the air assist tube or power lead) up to the module which does have the exposed circuit board, and there wrapping around the module body (perhaps even a plate of copper atop the unit..on that perspex plate..extending out a bit and folded down to shield the unit.
A test with a length of single core electrical cable and tinfoil could suffice, once the connecton between the pickup strip and the frame/gantry/module are effective and running off to earth (located where you wont get a charge comming back the other way, caused by lightning strike etc.
Apart from that, Its like only physical connections (small pins) or dust buildup (shorting) could be responsible, perhaps more ferite cores further along the power/signal path.
Thanks for the explanation.
The issue may not just be electrical noise from the cable, but also static buildup around the moving parts and the open electronics. I hadn’t thought about that kind of field effect before.
I’ll try running a grounding wire along the frame and gantry, following the power lead, and connecting it up to the laser module. I might also try the temporary test with a single-core wire and some tinfoil wrapped around the module, just to see if there’s any noticeable difference.
I’ll make sure to ground everything properly and safely to avoid any risk.
Also, I’m planning to buy an EMI filter for the power supply to further reduce potential interference.
So far, I’ve noticed that the issue mostly seems to occur during long engraving jobs like image burns. I haven’t experienced the problem during cutting operations since I installed the new cable.
Thanks again for your help
I’ll give this a go and post an update after testing.
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I recommend using silicone meter lead wire. It is very flexible and resistant to abrasion.
I’ve done several things since the last time I posted:
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I replaced the USB cable with a higher quality one, including ferrite cores.
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I updated the firmware to the latest version.
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I tested with another computer.
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I also connected the machine to earth, grounding the frame and the laser module.
Then I did some tests, and interestingly, after grounding the machine, I feel like I’m getting more connection issues than before. It seems like the problem has worsened slightly instead of improving.
So now I’m wondering if I may have done something wrong in the grounding setup, or if it could be causing some sort of interference instead of reducing it.
Without seeing any information on how you wired it up, no opinion is possible. Remove the ground that made it worse and see if it makes it unworse.
How long is the cable?
Can you describe how you did this?
it’s a 1 meter cable with two ferrite cores, one at each end.
For the grounding, I connected a wire to a screw on the laser head, then to the Y-axis rail, and from there to the main frame. Finally, I connected the ground wire to the earth pin of a wall socket.
I disconnected the grounding wire, and while it does seem to slightly reduce the connection issues compared to when it was grounded, I’m still getting random disconnects and connection error messages during use.
I’ve tried so many things, but the issue still comes back.
I’m starting to despair a little…
`Okay, you said a ferrite USB cable. this suggests you have a power line issue or an electrical device nearby that is creating your problem. Do you have something that draws a lot of power plugged in nearby. It does not necessarily to be in the same wall outlet.
- Has this problem existed from day one?
- I just thought about something else, have you turned off the energy saver option for USB ports?
Yes, I’ve already disabled the USB power-saving option in the device manager, so that shouldn’t be interfering.
And actually, yes the problem has been there since day one.
As for nearby devices, I do have a 3D printer, but it’s completely turned off when I use the laser.
Other than that, there’s just my Wi-Fi router, a smart home hub, and my laptop, which I place right next to the machine when I’m engraving.
I also tried using a different computer, and unfortunately I got the same connection issues, so it doesn’t seem to be PC-related either.
It seems that just leaves the controller board. Someone might suggest you “flash” the board (reinstall the operating software), but I prefer to replace the board. Maybe if you contact Sculpfun, they might replace the board, or at least offer a discount on a new one.
One is cheaper with more hassle, the other may cost with little installation hassle. If you decide to try flashing, Google S6 isken diode-wiki . @misken is the undisputed Guru for all of the Sculpfun machines.
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I had already flashed the firmware after finding this thread:
I also just contacted Sculpfun customer support to explain the situation and see what they suggest.
But honestly, I’m starting to think the issue might come from a faulty controller board.
I’ve tried so many things, and the problem still persists…
Replacing the board might be the only solution left at this point, unfortunately
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Great effort by you Manuel and lets hope it works out well.
What it could be is the USB socket on the controller board has a loose connection or a bad solder joint. I had to replace my 3018 CNC mill controller board because it came completely off the board. They are not really designed to support the weight of the cable.