Controller Software Redesign: A New Interface for Precision Extrusion

The Case for Redesign

The original Noztek controller software was designed for a simpler machine and a simpler use case. As the machines have grown in capability — more temperature zones, servo motor integration, expanded monitoring, connectivity features — the interface designed for a single-zone DC motor extruder has been stretched to cover scenarios it was not designed for. The redesign started from first principles: what do users actually need to do with the controller, in what order, and what information do they need visible at each stage?

Interface Structure

The new interface is organised around three views that reflect the natural workflow of an extrusion run. The Setup view handles material profiles, temperature setpoints, and screw speed configuration. The Run view displays all live process data in a clear layout that makes deviations immediately visible. The History view shows the log for the current run and provides access to the data export function. Navigation between views is immediate — no submenus, no confirmation dialogs for routine transitions.

Improved PID Control

The temperature control algorithms have been revised to improve stability during ramp-up and to reduce overshoot for materials with narrow processing windows. The PID parameters are now auto-tuned by a built-in routine that characterises the thermal response of the installed heater and barrel combination — producing settings optimised for the specific machine configuration rather than a generic default.

Update Availability

The controller software update is available as a free download for all Noztek machines with the current generation controller hardware. The update is applied via USB. Machines shipped from this date have the new software installed as standard.