1073507920 in hex is 3FFC6E50, which looks like a pointer. Are you sure you're not overflowing something else somewhere?

You might be better off also asking sales@espressif.com .

WiFi always needs some buffers (e.g. dma descriptors) to be in internal memory. Maybe you somehow managed to fill up your internal memory by so much that it cannot allocate that?

Nope, it's the nature of the beast: transmitting data or beacons or whatever takes current, and the ESP32 needs to do that at certain times. You can add capacitors or filtering if it affects the rest of your circuit, but the fluctuating current use itself is inevitable.

ESP-DSP has features for this. Easiest to use may be this (although the FIR variants are hardware accelerated, if you need that)

Hm, these things aren't really specced (but USB specs give an impedance of 28 ohm min, meaning worst case you'd have 100mA flowing into the pin, which feels like it should not be a problem) but why not simply allow your device to be fed from the 5V USB power supply as well?

Could be an ESD issue. The ESP32 has internal snapback devices, but seeing you don't have extra protection and you have touchable surfaces on your build (screw terminals for USB) you may have zapped your ESP32 with static electricity. (Although I'd check the obvious issues first: perhaps something g...

Might be a bad module; it's known that some manufacturer of boards marked as C3-supermini messed up their routing leading to crap WiFi performance.

Can you be a bit more specific what you need help with? It's usually easier to do so if you ask specific questions, rather than just stating 'I need help!'

Is it correct that using the "native" USB connection (so the "UART" flash method seems misleading to me) I don't need to control GPIO0 and RST at all? I can also remove the push-buttons on my board to manually force them? Mostly, yes. The internal USB-serial-JTAG converter can usually get your ESP3...