Design of Control System for 3D Printer Based [627469]

Design of Control System for 3D Printer Based
On DSP and FPGA

Dima Younes
School of Mechanical and Electronic Engineering, Wuhan University of Technology , Wuhan , China
Email: [anonimizat]

Tan Yuegang, Cheng Xin, Essa Alghannam, and Amjad Altazah
School of Mechanical and Electronic Engineering, Wuhan University of Technology , Wuhan , China
School of Information Engineering, Wuhan University of Technology , Wuhan , China
Email: {ygtan , chengx, essaalghannam} @ whut.edu.cn and [anonimizat]

Abstract—3D printing technology is a rapidly-evolving field,
which has seen an explosion of interest in the last decade
due to the influence and great degree of maker movement
and the rapid prototyping . A set of specialized print control
systems is the basis for the fabrication of electronic
technology. The use of closed-loop control to improve
performance in robots is a well-established technology, by
adding the necessary sensors and computational hardware,
it is easy to establish a low-cost and efficient 3D printer
system. Success of a motion control systems depends not
only on the controlling algorithm but also on the control
hardware structure. Compared with common robot
manipulators, 3D printer system has a more open-ended
structure, which needs the control system to be flexible to
the flexibility in 3D printer system. Based on DSP and
FPGA, unique flexibility and excellent control capability of
the motion controller can be designed to fit the
requirements of the flexibility in 3D printer system. In this
thesis, a kind of closed-loop control structure based on DSP
and FPGA for 3D printer has been proposed. The main
contents include: (1) the analysis of mechanical parts of
common low-cost commercial 3D printer and its
requirement for control system. (2) FPGA and DSP can
inherently handle processes in parallel, therefore a kind of
closed-loop control system has been designed to execute G-
code, compute curves and accelerations, and drive multiple
stepper motors simultaneously. The thesis illustrates the
frame of control system, and provides the design of
hardware circuits and software architecture. (3) The linear
acceleration and deceleration algorithms of multi-axes have
been analyzed, and the simulation results of trajectory
following by closed-loop control prove the efficiency of the
work in this thesis. The limited contributions of this thesis
include, (1) a kind of design of hardware and software for
3D printer system based on DSP and FPGA; (2) the analysis
of motion control of the multi-axes implemented in this
control architecture. The platform developed seeks to
increase awareness of the potential for the integration of
closed-loop control into existing open source designs and
will help to improve the performance of the low-cost 3D
printer system. 

Index Terms —3D printer , motion control , FPGA , DSP ,
stepper motor , closed loop

Manuscript received February 2 1, 2018; revised April 23, 2018. I. INTRODUCTION
Controlling our environment and the things around us
has been one of the fundamental goals and one of the
greatest achievements of the human endeavor. The
motion controller acts as the brain of the driving system
by taking the desired target positions and motion profiles
and then creating the trajectories for the motors to follow,
which is a numerical control instrument in general.
Unique flexibility and excellent control capability of
the motion controller results in effective application of
lots of industrial instruments. Benefit from the
development of high performance and high speed
processor such as digital signal processor DSP and
programmable logic device FPGA, motion control
technology is enormously enhanced [1].
A Field Programmable Gate Array (FPGA) based
system is a great hardware platform to support the
implementation of controllers such as PID controller,
fuzzy controller, adaptive controller, optimum controller,
FIR filter and even neuro network system [2], [3].
The system developed by Takahashi and Goetz [4 ]
could run a current control algorithm with a Xilinx FPGA
to increase the bandwidth of the current loop control.
Tzou and Kuo [5] performed the vector and velocity
controls of a PMAC servo motor by using FPGA
technology successfully. Other works on FPGA based
motion controls include Paramasivam [6], Bielewicz [7]
PID control was used as the control algorithm in these
works.
The controlling of speed is also one of the important
portions in motion control. In particular, it refers to
acceleration and (or) deceleration controlling. Daniel
Carri ca [8] has proposed a recursion algorithm for
applied on FPGA, the algorithm proposed avoided the
complexity in computations but at the same time
increased the loads on digital device. Ngoc Quy Le [9]
also proposed an algorithm for controlling variable speed
and it has been implemented on DSP by using the closed-
loop technique. For this algorithm, the control precision
has been improved, but it was just tested in lab without
any loads connected to the stepper motor, besides the
40Journal of Automation and Control Engineering Vol. 6, No. 1, June 2018
©2018 Journal of Automation and Control Engineering
doi: 10.18178/joace.6.1.40-46

speed curve generated by algorithm was not fine in
continuity.
The above mentioned algorithms are somehow
complicated with less efficiency. If we are to consider
that the moving units would move with large loads t low
speed, but at the same time demand high precise
positioning and accuracy, which means more measured
data to be in process. this paper chosen the trapezoidal
curve speed control mode [ 10], by using motion control
closed loop by adding a position feedback unit, then
proposed a novel algorithm to directly control both speed
and position which had been implemented on FPGA and
DSP.
For the linear translation levels using stepper motor,
the motion control is typically implemented by computers
and (or) programmable logic controllers (PLCs), using
open loop technique, however, for high accuracy and
efficiency applications, this would not be suitable any
more [ 11], [12].
One of the biggest problems faced in any CNC
machine or 3D printer is the missed steps while moving
the tool head. In this paper we focus on low-cost 3D
printers, generally with a price tag under 2000 USD. In
general, for 3D printing electronics are broken down into
4 different areas, the controller, stepper motors, stepper
drivers, and end stops.
Some authors designed dedicated embedded program
for control system based on a modern and efficient
STM32F4 microprocessor family that gave a substantial
contribution to the development of a new branch of the
three-dimensional printing. They used to 32-bite
STM32F4 unit with popular open-source project called
marlin and teacup for 3D printer [13].
In this project, we have designed an embedded system
based on FPGA and DSP control board to control a 3D
Printer. As we know, on a low level the basic operations
and processes executed by a 3D printer are pretty simple.
For example, stepper drivers need direction information ,
heaters need turning on and off and so on and this is
straightforward for a microcontroller. However, what is
hard for a 3D printer is the high level things. Calculating
the acceleration curves to minimize time take, while
maximizing the print quality. Tuning the PID loop for the
nozzle and bed temperatures. Moving information to and
from a computer or SD card. As we know
Microcontrollers are not able to handle things in parallel
what it means it can’t execute se veral commands at the
same time and also some microcontrollers couldn't fit all
the mathematics and calculations into the available
memory. Most microcontrollers-based designs will have
slight delays when trying to drive everything at once and
this would introduce some mechanical jitter.
II. MECHANICAL ANALYSIS AND CONTROL SYSTEM
REQUIREMENTS
The objectives and importance of the work can be
described together as below:
Build the structure and assemble the parts of the 3D
printer from a pre-designed model. Design and
implement a flexible, compact, high-performance and closed loop control system based on FPGA+DSP to drive
the various activities of a 3D printer being used.
The reason for the use of FPGA+ DSP can be
illustrate d that: The traditional DSP uses a Von Ne umann
structure and some type s of extension. This structure is
essentially serial, which it cannot deal with. FPGA
hardware can process in high speed, and can also process
a large amount of data, just to make up for the
shortcomings of DSP. DSP + FPGA system has the
advantages of flexible structure, strong versatility,
suitable for modular design, which can improve the
efficiency of the algorithm; at the same time its
development cycle is short, the system is easy to maintain
and expand, suitable for real-time signal processing.
By using displacement sensors, the information of the
actual motion along the X, Y and Z axes of the 3D printer
are read and used as the inputs for the closed -loop
controller which can modify the commanded position of
the stepper motors to reduce the position errors. Analog
to digital converter unit embedded inside DSP is used to
read the sensors signals . Such system would improve the
accuracy of the printed parts by correcting the mechanical
error in the motors steps size, as well as catching and
correcting missed steps, which enables the stepper motors
to be tuned more aggressively and increase the speed of
printing process. Thus the system is less cost, simple and
easy to implement. In this system PWM technique is used
to control the motors position precisely. The present work
is also concerned with providing methods to the
trajectory generator of the 3D -printer. FPGA and DSP are
used as a control core to solve the path planning problems.
A. Mechanical Analysis
The model has been bought from the internet. The
electronic parts such as the stepper motors and their
driver circuits, and the mechanical components such as
the metal rods and screws were purchased online from
internet. These components include gears, mounts for
various motors, the extruder housing, belt holders, and
various other connectors.
Once all of the parts had been obtained, we began
constructing the printer. The frame was assembled to
form a basic rectangular frame. The printer after
assembling in work place shows in “Fig. 1”.

Figure 1. The structure of 3D printer after assembly.
Following the frame’s construction, the X, Y, and Z
axis and their components had to be constructed and
affixed to the frame in their relative positions. The Y axis
41Journal of Automation and Control Engineering Vol. 6, No. 1, June 2018
©2018 Journal of Automation and Control Engineering

was controlled by moving the bed of the printer forward
and back, while the X axis was controlled by moving a
suspended carriage that held our extruder left and right.
Finally, the Z axis was obtained by moving that
suspended carriage up and down. Below is an explanation
of these aspects of the construction.
B. Stepper Motors
Unlike brushless DC motors which operate in
continuous once they are supplied with power, stepper
motors on the other hand would run in discrete step
angles. So we could say that a stepper motor is a
brushless motor that divide the full rotation cycle into a
number of steps. The stepper motor contains of a soft iron
shaft surrounded by electromagnetic stator. Both rotor
and stator have poles. When the stator is powered the
rotor moves to align itself with stator or rotor moves to
have minimum gap with the stator. Thus to run a stepper
motor the stators are powered in a sequence. Hence we
provide pulses to motor driver that will create this
sequencing.
The figure below shows a NEMA 17-size hybrid
stepping motor can be used as a uni-polar or bipolar
stepper motor and has a 1.8° step angle
(200 steps/revolution). Each phase draws 1.2 A at 4 V,
allowing for a holding torque of 3.2 kg-cm (44 oz-in).

Figure 2. NEMA 17-size hybrid stepping motor.
III. HARDWARE AND SOFTWARE DESIGN OF THE
CONTROL SYSTEM
We use the 3D printed model created with CAD
software to get model of one real object. And to process
the data through the host computer, which controls the
peripheral circuit system. We run repetier software in the
host computer to make STL file into G-Code in the end.
The host computer handles the raw data and controls the
lower computer. The lower computer, which based on
FPGA and DSP, is the control core of the printing system.
It is mainly responsible for the control of the X, Y, Z axis
movement of the motor. Then Let the machine reach the
specified location accurately and finally print completed
object. The whole flow chart is shown in “Fig. 3”.

Figure 3. The flow chart of 3D printer. A. Electronic Design
Once the printer had been fully assembled, all
components had to be wired and tested to make sure they
all functioned appropriately and had full functionality.
Our 3D printing control board which shown in Figure 4 is
controlled by using FPGA in combination with DSP. It
can control up to 5 stepper motors with 1/16 stepping
precision and interface with a hot end heater, a heated bed,
a fan, a LCD controller, a 12V power supply, up to 2
thermistors, up to 3 end stoppers (Limit Switches), and
serial communication with computer via RS232 protocol.
We use DSP: floating – point processor TMS320F28335
and FPGA: ALTERA / Cyclone3 / EP3C5E144C8N.
The driver board is designed by Altium Designer
software and it contains all the interfacing circuits which
connect the FPGA+DSP board with the other components
such as stepper motors, sensors, heaters, fans, and LCD.

Figure 4. Control board.
B. Control System of 3D Printer
The computer inputs control signals to the lower
computer through outputting electrical pulse s. The
control system bases on FPGA and DSP as the master
chip as shown in “Fig. 5 ”.

Figure 5. Structure of peripheral circuit.
The computer will send the instructions to the DSP
chip through the circuit interface. And The DSP will send
multiple PWM pulses to FPGA through XINTF. FPGA
gets control impulses from I/O pins and sends control
pulses to sensors of peripheral circuit. After that the
peripheral circuit will send feedback signals to the DSP
chip immediately. Through all this above, the whole
system realize s a closed-loop control process finally.
42Journal of Automation and Control Engineering Vol. 6, No. 1, June 2018
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FPGA controls the hot bed heater and extruder heat er
by controlling the waveform of PWM. And The
temperature sensor tests temperature of those mentioned
above and sends feedback signal s to DSP. The DSP chip
understands this data by Analog to Digital Converter ,
which was embedded in DSP chip. The same principle
that the ultrasound sensor get the distance data and sends
feedback signal s to DSP, too. Moreover, travel switch can
send feedback signals to the GPIO of DSP. In turn the
DSP will control peripheral circuit by sending PWM
pulses to FPGA. And the FPGA will control peripheral
circuit directly. The system will remain in a dynamic
equilibrium range.
C. Software Architecture
The process of 3D printing in the part of software is
shown in “Fig. 6 ”. Firstly, we confirm the model we
want to print and extraction detailed parameters of his
appearance. Then we create a 3D model, which repetier
can understand, by programs like 3D MAX, Pro/Engineer ,
and Rhino. And we also can create the model on repetier
directly. Then repetier will slice the model into thin
layers and export the G-code, which contain the features
of the model, into command, which the driver circuit can
understand. In the end, the three motors will move
orderly through the system.

Figure 6. The process of 3D printer in the part of software.
The speed control of stepper motors flow chart is
shown in the “ Fig. 7”. After the program begin, the MCU
will get the speed set of motors. Then the MCU will
calculate the pulse frequency we need and convert to
clock cycle division factor. Then update the timer
division factor, registration timer interrupt, generate
pulses in the interrupt response in the end. The speed of
the motor can be obtained from the beginning, if we want
stepper motors work in a new set of speed, then the
program will convert the pulse frequency, which can output appropriate PWM pulses to driver stepper motors
the speed set, into the clock division factor . The
coefficients are updated and pulses are generated in the
interrupt function , then the motor correspond to the speed
set. Then the system will judge the speed of motor
whether is right. The wrong speed will be corrected by
the control system.
The displacement control of the stepper motors is
shown in the “ Fig. 8 ”. We Firstly, control the motor to
run at a defined speed, and then calculate the time of this
motion and driver the motor, starting the timer at the
same time, When the time run out stop the motor, so as to
achieve displacement control. This part of is mainly for
providing interfaces in the axis linkage system later.
Finally, we will measure the place of motors by sensors,
the wrong displacement will be corrected by the control
system.

We choose Quartus II as the development platform for
this project. Quartus II is one kind of development
software, designed by Altera, which is competent to
comprehensive PLD / FPGA, schematics, VHDL, Verilog
HDL and AHDL (One language that Altera Hardware
Support) and other design input forms, embedded in the
existing synthesizer and emulator. We can complete
designs of PLD flow chart into the hardware
configuration.
A. Linear Acceleration and Deceleration Algorithms of
Stepping Motors
The control system chooses the trapezoidal
acceleration/deceleration algorithm to control the motion
of each stepping motors. Trapezoidal algorithm is a
straight line acceleration and deceleration, which can run
stably, and meet the rapid changes of motors of the speed
and position s. At the same time, the algorithm is easy to
implement, the control is simple and the calculation is
effective. The curve of the trapezoidal acceleration /
deceleration algorithm is shown in “Fig. 9”. Figure 7. Flow ch art of
motors speed control . Figure 8. Flow chart of
displacement control .
control .
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t
tv
a

Figure 9. Trapezoidal acceleration and deceleration .
From the above figure we can see that the process of
stepper motor speed change is in three stages:
acceleration, uniform and deceleration. Its displacement
of the acceleration and deceleration can be expressed as:

2
max
2abvSSa
(1)
B. X-Y- Axis Simultaneous Motion Algorithm
Since the hot end heater of 3D print er are moving on
the work surface following the printing path, it is
necessary to control the motors to move at the direction
of X-Y-axis simultaneous ly. Because of the trajectory of
the stepper motors can be decomposed into a large of
discrete points, and the movement of motors in adjacent
discrete points can be described as a linear motion. So the
X and Y axis displacement can be decomposed into two
linear motion, as shown in “Fig. 10” below, Where the
coordinates A and B are adjacent coordinate points, and
the hot end heater will move from point A to point B.

Figure 10. The movement of hot end heater.
We must ensure that the stepper motors of X and Y
axis run and stop at same time. Assuming that the
displacement of X-axis is Sx, its velocity is Vx, the
displacement of Y axis is Sy, its velocity is Vy, and the
following relationship exists:

xx
yyvs
vs
(2)
C. Simulation of Trajectory Following by Closed-Loop
Control
We use a PID controller (proportional –integral –
derivative controller) to get precise trajectory. The system and controller are assumed to take the form shown in
“Fig. 11”.

Figure 11. Controller block diagram.
Through Matlab simulation, we analyze the feature of
PID controller. A better test of performance involves
measuring the system’s ability to follow a series of move
commands. Formulated as G-Code, these commands
replicate motions found in a real- world print. “Fig. 12”,
shows the system’s performance in following a circular
trajectory composed of linear segments, both in command
trajectory and closed-loop. the trajectory was generated
as G-Code and run at 30 mm/s. The mean trajectory error
(the distance between each data point and the command
trajectory location at that point, then average these
quantities) is given as the following expression:

  
22
01( ) ( ) ( ) ( )N
t t t
ie x i x i y i y iN   

(3)

The PID closed-loop controller has a mean error of
0.07 mm, so PID controller can make system work better
surely.

Figure12. PID circle tracking and tracking set.
IV.
EXPERMENTAL WORK
We import 3D model (cube) that created with CAD
software, which repetier can understand it and makes
STL file. Repetier slices the cube model into thin layers
by slicer as is shown in “Fig. 13”.

44Journal of Automation and Control Engineering Vol. 6, No. 1, June 2018
©2018 Journal of Automation and Control Engineering

Figure 13. The slicing.
“Fig. 14” shows The G -code that contains the features
of the cube model, and this G-code exports into
commands which the driver circuits can understand.

Figure 14. The G-code.
Finally, the driver circuit sends the commands to X, Y,
and Z motor which in turn moves as linear motion and
prints the cube model layer by layer until finish the whole
shape as we see in “Fig. 15”.

Figure 15. The printed cube in work place.
V. CONCLUSION
The main works are about a design of control system
based on FPGA and DSP for 3D printer. By the usage of
a powerful logic function and open system scalability,
reconfigurable features, an open-ended control structure
can be established. Although it’s different in the number
and type of axes as well as the type of programming and internal control system, the requirement of multi-axes
motion control is similar and can be combined into a
unique architecture. The main works in this paper include,
 Build the structure and assemble the parts of the
3D printer from a pre-designed model. Through
the analysis of mechanical parts of common low-
cost commercial 3D printer and its requirement for
control system, then a kind of control system
architecture based on DSP and FPGA has been
proposed.
 The thesis clarifies the frame of control system,
and supplies the hardware circuits design and
software architecture. based on that FPGA and
DSP can treat the processes in parallel inherently,
the mission of motion control of multi-axis can be
split into many parts according to the architecture
of software, and the closed-loop control system
has been designed to execute G-code, compute
curves and accelerations, and drive multiple
stepper motors simultaneously.
 The process flow of the closed-loop control
system has been provided, and the control
strategies of acceleration and deceleration of
multi-axes has been designed with the path
planning method to explains that how to control
the 3-axis and how the endpoint trajectory is
generated based on the control of each axis. the
simulation results of trajectory following by
closed-loop control prove the efficiency of the
work in this article.
This article has completed the overall design of 3D
printing, but the lack of individual experience in personal
practice, coupled with the limitations of time and
laboratory conditions, in the whole process there is still
some problems and the system are not good enough. The
following points are suggested for further developments:
 Further development of high -precision motion
control system (which can use dedicated motion
control board), so that the movement system and
inkjet printing system do not need to interfere with
each other, to facilitate better maint enance updates
and further upgrades.
 The slicing algorithm can be refined and refined
into the 3D printer within the master control
system, in order to achieve the computer and the
printer into one.
 The foremost area of future work centers on the
development of more accurate, better-performing
control algorithms. Getting the more complex
controllers described here and elsewhere in the
literature will be a major step towards realizing all
that closed-loop control is capable of.
ACKNOWLEDGMENTS
This work was financially supported by the National
Key Research and Development Program of China
(2016YFB1101701) and the Fundamental Research
Funds for the Central Universities (WUT: 2017II26GX).
45Journal of Automation and Control Engineering Vol. 6, No. 1, June 2018
©2018 Journal of Automation and Control Engineering

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Dima Younes was born in January 1987 in
Syria . She received h er master’s degree in
Instruments Science and Technology from
Wuhan Univers ity of technology , China, in
2017. She received her bachelor degree in
electronics engineering from Tishreen
University, Syria, in 2010.
From 2010 to 2014 she has been a research
associate teacher at the School of Mechanical and Electrical Engineering, Tishreen University, Lattakia, Syria. She is
currently a Ph.D. student at the School of Mechanical and Electronic
Engineering, Wuhan University of Technology, Wuhan, China. Her
research interests include electronic design automation, embedded
systems and its applications.

Tan Yuegang was born in 1959 in China . He
received his Ph.D. in mechanical engineering
from Wuhan University of Technology, China,
in 2005. He received his bachelor’s degree
and master degree in mechanical engineering
from Chongqing University, Chongqing,
China, in 1983 and 1989.
He is majoring in mechanical manufacture
and its automation, professor, Ph. D
supervisor, member of Electronic and
Mechanical Engineering Branch, Chinese
Electronics Association; editor of “Electronic and Mechanical
Engineering”, director of Hubei Mechanical Engineering Design and
Transmission Association, director of Wuhan Mechanical Design and
Transmission Association. His research area mainly covers robot
control technology, mechanical system analysis and control, machine
vision and its application.

Cheng Xin was born in China. He received
his Ph.D. in Mechanical and Electronic
Engineering from Huazhong University of
Science and Technology, China, in 2011. He
received his bachelor’s degree and Master
degree from school of information
engineering, Wuhan University of Technology,
Wuhan, China, in 2004 and 2007.
He has been working in school of
mechanical and electronic engineering,
Wuhan University of Technology from 2011. His research area includes
magnetic suspended bearings and high-speed and high-precision motion
control.

Essa Alghannam was born in December 1987
in Syria. He received his master’s degree in
mechatronics engineering from Wuhan
University of technology , China, in 2015. He
received his bachelor degree in mechatronics
engineering from Tishreen University, Syria ,
in 2010.
From 2010 to 2012 he has been a research
associate teacher at the school of
Mechatronics Engineering, Tishreen
University, Lattakia, Syria. He is currently a
Ph.D. student at the School of Mechanical and Electronic Engineering,
Wuhan University of Technology, Wuhan, China. His research interests
include robotics, robot vision, and human interface.

Amjad Al Tazah was born in August 1987 in
Syria. He received his bachelor degree in
communications and electronics engineering
from Tishreen University, Syria, in 2010. He
is currently a master student at the School of
Information Engineering, Wuhan University
of Technology, Wuhan, China. His research
interests include embedded systems and its
applications.
46Journal of Automation and Control Engineering Vol. 6, No. 1, June 2018
©2018 Journal of Automation and Control Engineering