Okay, well, an update on this:
The problem continued throughout the weekend run, and nothing I tried fixed it, not even eliminating the Presonus completely and just going out of the headphone jack.
The problem happened on 4 different tracks, but none of them consistently. Two were .wav files, and two were mp3s
It happened with the presonus digital output, but also with the headphone jack into a mixer.
It happened on two different laptops with different hardware (2015 Macbook Pro Intel i7 and 2022 Macbook Air M2) and Operating Systems (High Sierra and Monterey)
It happened on two different versions of Qlab (4.62 and 4.7)
It continued after bumping the audio device buffer size to max (1024) on both the headphone jack and the Presonus.
It continued in Show mode vs Editing mode - my attempt to eliminate underlying apps or programs using resources.
I haven't yet managed to reproduce it when using the internal laptop speakers.
I ran the last show with verbose logging, but haven't had a chance to look at the console yet to see what it said.
The only thing I can think of is that somehow my show was corrupted in the original build? I didn't try re-importing the tracks and starting over, but I may try that this week, just to get some peace of mind about what was going on. This is the first time in more than twelve years of using Qlab that I had issues I couldn't resolve and was on edge about it. It was not a fun experience, but also reminded me what an absolute gift it's been for all these years to be able to trust it completely. I'll update once more if I finally figure out what was going on.
-Stephen