Most parts are routed 3D but I also use some 2.5d procedures. I use Mach 3 and am used to it but not a slave to it.
I think you would find that the Trajectory Planning for these types of Jobs is superior in KMotionCNC.
I understand that the Leadshine hybrids are supposed to help with better quality. But I don’t understand how sending the encoder signals to the computer helps.
I thought the Leadshine hybrids don't have encoder outputs to send position back to the Controller. Sending position back to the controller allows the Controller to monitor performance rather than only having a fault signal. It allows you to plot performance and check tuning. It also allows recovery without loss of position after a disable or fault. If everything is working well and the Drive has been tuned properly, and the drive never faults or is disabled, then there won't be any actual difference.
And have been urged to upgrade to this type of motor feedback and here is what I don’t understand.
There is a third party that produces a board that connects to Kstep and KFlop. I can identify it once you approve this first message.
I'm not sure what you are asking. KStep is a traditional Step/Dir type of Stepper motor driver. When using KFLOP + KStep to drive your motors you can also add encoders and connect the encoders back to KFLOP.
Can you help me set up my new upgraded hardware and software or advise me if other things might be needed.
You will need to setup your hardware and software yourself. We can provide some help and answer specific questions.