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So further to this - the board came in whilst I was down in Melb earlier in the week, thank you Alan!Thanks mate. Will dig in deeper and definitely let you know results. It's an interesting one for sure.
I have done some testing tonight and I can repeat the results. It certainly "feels" like it's a DMX decoding issue due to the way when the channels flip, the brightness carries across. i.e. if Ch3 is set to 128, and Ch4 is set to 0, they swap. Likewise if Ch3 is set to 255, when it swaps, it blinks to full brightness.
Data rate matters too. If I push 24 DMX channels of data down the line, it happens much more frequently than if I push the full 512ch universe down.
I am having LESS issues now using an ESP32 with ESPixelStick driving it compared to what I had with the Falcon and USB Dongle driving it, so there must be some timing discrepancies between them, not surprising I guess.