To LegalEngineer -
TestStand does not have any specific limitation built into the application. Each execution has at least one OS thread associated with it. In addition, for each execution, TestStand allocates a lot of other resources for it, including a separate execution window in the sequence editor or operator interface. I have seen some instances with Windows where the operating systems does not do to well when an application has over 120 threads. Creating 192 execution threads in a single TestStand application is a lot and I suspect that the OS might not do so well with this.
When possible I recommend using a single execution with a lot of threads instead of a lot of executions each with a single thread.
You could try a simple testcase where you have a single execution loop on an async sequence call step that runs in a new thread. The async called sequence could then loop on a series of steps. Increase the number of threads you use to see how the OS performs.
Scott Richardson
https://testeract.com