Andy, any idea what current the original drivers were set at?
Regardless, it looks like you're running the motors within their ratings, so I wouldn't worry about it too much. You could probably drop the current a little bit more if you're concerned, but it really depends on how conservatively or hard you want to run things.

One thing that I keep wondering about, is why the microstepping setting never worked how it should. If it was because the DIP switch was faulty, then the current setting could also be an issue.
It's probably not a fault, but was the step per setting a problem for all axis?
And are all the steppers getting equally warm?


Lucan, even at that, you keep posting what sound like definitive solutions without getting all the facts, which could quite easily cause more problems than they solve.