Why Your Stepper Motor Skips Steps at High Speed

You design a CNC router. You calculate the steps per millimeter. You write the G-code. The motor should move 200mm per minute. At low speeds, it works perfectly. At higher feed rates, it starts skipping steps. The machine cuts crookedly. You blame the software. You tune the steps per mm. You try different drivers. The problem persists.

You have exceeded the torque curve of the motor. Not slightly. Fundamentally.

Stepper motor internals — torque drops as speed increases because the current cannot keep up with the step rate at high supply voltage limits.

Understanding the stepper torque curve is the difference between a machine that works and a machine that destroys your materials. is the difference between a machine that works and a machine that destroys your materials.

The Torque Curve Is Not Optional Knowledge

A stepper motor produces torque as a function of speed. As speed increases, torque drops. This is not a defect. It is a fundamental characteristic of how stepper motors work.

At low speeds (below 500 rpm on most NEMA 17 motors), the motor can produce its rated holding torque. At mid speeds (500-1000 rpm), torque drops to 50-70% of holding torque. At high speeds (above 1000 rpm), torque drops to 20-30% of holding torque.

Your CNC router needs maximum torque at the cutting edge. If your feed rate pushes the motor above the speed where torque falls below the cutting load, you will skip steps. No amount of software tuning fixes this. The motor is physically incapable of delivering the required torque at that speed.

This is why stepper motors are rated by holding torque, not running torque. The holding torque is what you get at zero speed. Running torque is a curve, and you must design your system to stay on the correct side of that curve.

Why Your Calculation Was Wrong

You calculated steps per mm from the motor specs and the pulley ratio. This is correct for open-loop positioning. But you did not account for the torque required to accelerate the mass.

Moving a motor at constant speed requires relatively little torque. Accelerating it from rest to target speed requires peak torque. If your acceleration is too fast, the motor stalls before it reaches the target speed.

The formula for required acceleration torque: T = I × α. I is the moment of inertia (mass × distance²) of everything attached to the motor shaft. α is the angular acceleration. If the load inertia is too high relative to the motor's rotor inertia, the motor cannot accelerate the load without stalling.

For a CNC router, this means the motor must accelerate the gantry, the tool, the workpiece, and the cutting force simultaneously. If your acceleration settings are aggressive (high α), the motor must produce more torque during acceleration than during the cut itself. Skip the steps during acceleration, and the rest of the cut is misaligned.

The Driver Voltage Matters More Than the Driver Current

Most stepper driver boards have a potentiometer to set the current limit. Setting it to the motor rated current seems correct. But voltage is equally important.

Stepper motors are inductance-limited devices. The current in each phase winding rises according to I = V / R × (1 - e^(-t×R/L)). At low supply voltage, the current rises slowly. At high supply voltage, the current rises quickly.

At low speeds, the step interval (t) is long enough for the current to reach full value regardless of voltage. At high speeds, the step interval is short. If the supply voltage is too low, the current never reaches the set value before the next step. The motor produces less torque.

This is why running a NEMA 17 from a 12V supply at 1000 steps/second produces much less torque than running the same motor from 24V. The current cannot keep up with the step rate.

Rule: supply voltage should be at least 3x the motor voltage rating for good high-speed performance. A 2.5V rated motor with a good driver can run from 24V if the current is properly limited.

Microstepping Is Not Free Torque

Microstepping divides each full step into 2, 4, 8, 16, or 32 sub-steps. This gives smoother motion and higher effective resolution. But it does not increase torque. In fact, microstepping slightly reduces the effective torque per microstep because the current is shared between two phases.

If you are using 1/16 microstepping and getting half the torque you expect, that is why. The motor can only produce so much torque, and microstepping is smoothing the steps, not multiplying the torque.

Use microstepping for positioning accuracy and vibration reduction. Do not use it as a workaround for insufficient motor torque.

The Real Solutions

Increase supply voltage. Going from 12V to 24V can double the torque at high speeds. Going to 36V or 48V can double it again. Use a driver rated for the higher voltage.

Use a larger motor. NEMA 23 produces significantly more torque than NEMA 17, and the larger rotor has higher inertia, which actually helps at higher speeds. Size the motor to the load, not to the budget.

Reduce the load inertia. If the gantry is too heavy for the motor, lighten it. Use aluminum instead of steel for non-structural parts. Reduce the pulley ratio so the motor drives more slowly but with more torque per unit of load movement.

Slow the acceleration. If the machine must operate at high feed rates, extend the acceleration ramp so the motor has time to build speed without stalling. Most CAM software has acceleration settings that are independent of feed rate.

Use closed-loop servo instead. If you need high speed with high torque and no skipped steps, stepper motors are the wrong technology. A servo with encoder feedback will never skip steps — it either achieves the position or it faults. The cost is higher, the complexity is higher, but the performance is in a different class.

The skipped steps are not a firmware bug. The motor is telling you it cannot do what you are asking. Listen to the torque curve.

For high-speed stepper systems:

NEMA 23 Stepper Motor 425oz-in — Nearly 3x the holding torque of a typical NEMA 17. Run from 24-36V for high-speed performance. (Amazon)

TB6600 Stepper Driver 9-40V — Supports higher voltage than typical A4988 drivers. Essential for maintaining torque above 800 rpm. (Amazon)

48V Power Supply for Stepper Drivers — High voltage supply unlocks the high-speed torque potential of properly rated stepper systems. (Amazon)

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Article #012, 2026-04-18. Content Farm pipeline, Run #012.