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To answer your questions would require delving into the source, unless someone emerges who already knows it. I think you're breaking new ground with a high bandwidth application. My experience with ESPNow is at the opposite end of the scale, where a device wakes up from deepsleep occasionally, sends an MQTT message, and dozes off again.

It's highly likely that the audio_out i2s buffer is under-nourished as your bit rate is so close to the MicroPython limit that we've both measured.

I'm not sure what to suggest. Options are:

  1. Reduce the bit rate (probably unacceptable).
  2. Investigate how MP deals with ESPnow and propose improvements.
  3. Consider using C.

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@peterhinch
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Answer selected by Schneckensuppe
@glenn20
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@glenn20
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