you should be able to get to about 98% * before you hear crackles IF the cpu load is split evenly across audio callbacks.
* this requires setting the --high-performance-mode command line option in the project settings. When running in this mode with high CPU usage, the IDE will most likely become unresponsive while the program is running and so in order to stop the running program you have to press the button on the cape.
mrnavigator5000 I was getting Underrun detected: 1 Block Dropped in the IDE till I increased block size to 128.
this could well be a symptom that the CPU load is not spread evenly across audio callbacks.
removing the expr object is often a way to optimise a patch. In this case it would be even better as it would allow it to build wit heavy.
mrnavigator5000 What are the consequences/trade offs, if any, for increasing block size?
it increases latency, reduces some of the CPU overhead (i.e.: frees up some more CPU % for your code to run) and it allows to spread the CPU load more evenly.