What’s Coming in gSender

Hey folks, I’m excited to share some of the work the gSender team has been doing that’ll be coming down the pipeline as Edge releases soon.

gSender 1.6.3 was recently released, but maintenance is not the only thing the team has been working on – we’re continuing to develop new features on our internal builds to expand our capabilities or meet the needs of common customer requests.

Today, I’d like to show some previews of just some of these new features, available soon for testing as 1.7.0-Edge-1.

Visualizer Improvements

Philosophy

The visualizer has long been the centerpiece of gSender’s interface, letting users see their position, explore their toolpath and tool changes, and connect what’s happening on screen with the physical machine. That said, while it’s received a number of improvements over the years, it’s largely been the same component library.

With this upcoming release, we’ve rewritten the existing library for massive performance improvements and new functionality.

New Visualizer Features

We’ve added so many new functionalities we’ve had to add a new config section just to handle it all, with more to come! That said, let’s go through some of the new features:

Config keeps growing!

Bounding Box and Labels

gSender has long included dimensions of your toolpath as part of the file information section. However, it’s not always visible and some users might want to see it represented in the visualizer itself. We’ve added an optional bounding box and labels, to show dimensions in the visualizer itself. This includes min and max values for all 3 axes.

Bounding box and labels

More Colour Themes

We’ve added a number of new color themes to the visualizer to spice up how your toolpaths look. We plan to expand this with community offerings in the future.

Some new theme options

Sharper View

We’ve overhauled how toolpath lines are visualized along with webGL materials used. We’ve reduced the number of axis ticks to cut down on visual clutter and improve performance by reducing the number of sprites. Lines themselves should also look crisper than the previous implemenetation.

We’ve also added smoother camera controls, a fully 3d aware camera cube that lets you easily jump to faces, and better motion control on touch – which adds up to a much nicer experience when interacting with the visualizer.

New Visualizer

Better SVG Visualization

SVG visualization should be more performant, due to us aggressively deduping XY coordinates at different Zs. We’ve added a bounding box, and a reference point for where the toolpath zero is located, which is information that was missing in the previous implementation. It’s also now theme aware and includes tool change colors for any files with M6 commands.

On top of that, a simple crosshair now tracks position when running a job – so it’s not just a static image anymore, its a fully usable option when interacting with your CNC.

SVG Visualizer update

Machine Boundary and Keepout Indicators

One of the more confusing aspects for new CNC owners is the distinction between workspace coordinates and machine coordinates. With the new machine bed outline and trimming grid options, your visualizer is now a much closer representation of your machine in 3d space.

If your CNC has homing capabilites, when setting a zero, your visualizer will update to show where the toolpath will cut according to your max travel values, making it much more obvious if you run the risk of going outside your limits.

On top of this, if you have an ATC, the keepout area is highlighted, so you’re more aware of the potential to run into that before it happens.

Bringing the visualizer closer to the machine’s actual 3D workspace should make positioning and machine limits much easier to understand, especially for newer CNC users.

3D Visualization

Not ready for Edge-1 but in the works is an even newer way to view your toolpaths – fully 3D! Know what your toolpath should look like before you cut a single chip. We’re not 100% sure where this will integrate yet, but we’re likely looking at a way to step through your file and see the end/in-progress results ahead of time.

Ramming our new visualizer down your throat

Plugins

Philosophy

One of the hardest parts of developing software such as gSender is determining which features we want to add next. Sometimes, functionality is so commonly requested that working on adding it just makes sense. Other times, it’s determined by engineering projects in-house, such as the ATC, which lead to a host of features in gSender. The hard part is determining how and when to tackle the lesser requested features – because not every feature is useful to every user and we don’t want to stray too far from the core value of gSender as an easy-to-use sending software.

Due to this, we’re adding a Plugin system to gSender. A plugin is a standalone tool, usable within gSender, to accomplish any goal the developer sees fit. Plugins are shareable, letting users pick and choose what they want in their sender software.

This also lets the community at large develop features at their discretion for their specific use cases.

One major benefit is that this means functionality can be added to gSender outside the boundaries of major or minor releases – so both community and in-house plugins can become available more often than our normal release schedule.

We’re still honing the user experience, but the goal is to have installing (or removing) a plugin as easy as point and click within gSender, with the ability to disable and remove a plugin with no further issues. Installed plugins are accessible via the Tools page, and managed via the plugins tool.

#image_title

We’re excited to see what the community at large can developer for gSender plugins – but we also have some samples to show off.

Plugins show up as tools

Sample Plugin – Simple Line and Shape CAM

3D Printing has Benchy as a first project, but CNC doesn’t really have an equivalent. You’ve setup your machine, installed your software, and have no easy way to enjoy the fruits of your labour without a massive context switch to some design software. It’d be nice if you could setup a simple project that you can run right away.

The basic cam plugin lets you do this. Setup a triangle, maybe some text, and you’ve got a basic sign – all from within gSender.

We’re going to continue to expand this tool to add a few more options (text coming, for example), but that’s the vibe and philosophy behind it. We hope other plugins that generate more complex g-code will be developed and shared by the community.

Simple cam is simple

Sample Plugin – Simple Sign Maker

One of the problems with onboarding CNC users vs 3D printing users is the context switch from setting up your hardware and software to designing and exporting something to actually cut to see your machine in action.

This plugin hope to address it by making it easy to add some text to a shape for a simple sign – so you can make chips fly and see the results of your efforts, and in the end get a little piece of wood with your name on it.

Pick a preset shape, pick your text and fonts, and you’re ready to carve.

I want to see chips

Adding or removing tabs is as simple as clicking on the profile – and they can be dragged around based on your workholding requirements

Tabbing out

… And yes, we have a benchy

Toot toot

Pendant UI

Philosophy

gSender has been a Raspberry Pi-friendly application since inception. That said, it’s primarily a desktop application, and has historically required a fair amount of processing power to run well.

With recent optimizations, we’re looking at exploring alternative ways to interact with gSender, and are working on a pendant-style view. Designed from the ground up with touch focus in mind, this new pendant view is an entirely new user experience that runs well on integrated CM4 modules.

Featuring noticeably larger buttons, a SVG visualizer, and newly reorganized tools in expandable drawers, it’s the same old gSender in an all new responsive, and touch-forward view.

We hope to have this specific configuration available as both a standalone application and usable within main gSender proper for those who prefer it using an opt-in configuration.

We are internally exploring providing a bespoke CM4/touchscreen offering as a more affordable alternative to the gControl panel computer in the future using this specific application. That said, the application itself will always be free – and installable/usable on the gControl if you already own one and prefer this form factor.

Pendant in Action

Connection and Job Loading

Connection has been redesigned to be touch focused – one click to list, one click to connect, and you can hold to disconnect.

Machine status has been redesigned to be less intrusive, and includes a number of new animations depending on firmware state.

The visualizer itself is smaller, and limited to a top down view – but you still get important information like the origin and location as the job runs, along with various toolchanges.

Connecting and jogging around

Tool Drawers

Most of the functionality has been moved into expandable drawers that are only visible when you need them. Drawers have 2 states – partial and fully expanded.

Partially expanded should be the quick info and actions you need. For example, for the file tab it’s the file info like name and bounding box.

For the fully expanded, it’s more rare configuration options or other functionality. As an example, when the file drawer is expanded with no file loaded, you get a full list of recent files. If a file is loaded, you get the contents of that file and the g-code editor.

Same philosophy for the probe drawer – partial expanded shows your current probe configuration and lets you just hit go. When fully expanded, you get a touch friendly guided process to configure your probe diameter, probe corner, and check continuity before running.

Don’t drop your drawers, expand them

Other Small Things

There’s a number of other features you may notice in the upcoming Edge release.

We’re expanding the helper to better tie into our resources, so if you get an error or alarm you’re better equipped to deal with it.

A number of new config options, including probe retract speed and backup settings directories are added.

Remote mode now will automatically connect to an open Desktop connection – so no need to reconnect a second time on your remote client be it your phone, tablet, or a shop PC

There’s an added benefit to this for remote users – imagine designing something in a plugin connected remotely on your desktop PC, and with one click of “Load to gSender” it’s already loaded on the desktop client of your shop PC, ready to carve!

We’ve also made a host of bug fixes, UX improvements, and tweaks to dark mode. There will be a more comprehensive list of changes and new features in the official post on release.

…And Much Much More

This is a quick overview of some of the features you can expect in the upcoming Edge-1 release. We also have a number of future improvements and features we can’t wait to share with you – but that’ll have to wait until the next blog post.

We’re really looking forward to the community getting their hands on this version and giving us their feedback. No firm date, but mid-August seems likely for public release – although everything is available on Github for testing now, if you’re technically inclined.

gSender 1.6.3

Cartoon dog in an astronaut helmet sits on a moon-like rock against a dark space backdrop, promoting gSender 1.6.3 new release.

Hey folks, gSender 1.6.3 with a number of fixes, behaviour improvements, and features.

Here’s what’s included in this update

New stuff you can use

  • Support for the new LongMill MK3 profiles.
  • A new flashing option for the upcoming SLB-Lite using UF2
  • A new TLS installation wizard, found in the Accessory Installation tool. It walks you step by step through picking your probe locations and setting up your toolchanging routine.
#image_title

  • You can now set a custom feed rate for the final probe movement, instead of it always using the default Rapid speed.
  • The SD tool now lets you upload several files at once instead of one at a time.
  • The toolchange wizard now shows a “pending” state while it’s finishing up moves, and it pops up a little closer to when the actual tool change happens, so it feels more natural.

Smoother and more reliable

  • Changing toolchange or passthrough Config settings now applies right away, no more reconnecting or reloading your file.
  • Fixed a laser/PWM issue so it works properly without unexpected spindle behavior on grblHAL
  • Feeder Position variables pos{axis} and mpos{axis} are now always converted to millimeters, even if your machine is set to report in inches (13=1)
  • Homing status shows up more consistently for machines that are already homed when you connect.
  • Tool Timeline Probe status now considers non-0 values probed, not just negative values.
  • Job progress is easier to read with a new background behind the line count.
  • Made several changes to prevent your Config settings file (sender_rc) from getting corrupted, and if it somehow does, the app will no longer fail to start.

Firmware profile updates

  • Updated to support the latest grblHAL firmware, including changes to how lasers and PWM work.

Bugs squashed

  • Fixed the tool timeline showing the the original, non-remapped value when minimized
  • Fixed a probe dialog bug where connectivity tests would falsely show as passing if enabled when opened
  • Fixed a display issue in the Config tool when undoing changes to certain values.
  • Fixed the single-axis homing toggle appearing when homing disabled.
  • Fixed the park shortcut to worked when the firmware reports homed status
  • Fixed job progress not updating properly after tool changes pausing progress.

Full Changelog

  • Added LongMill MK3 profiles.
  • Added flashing path for new SLB-Lite using $UF2.
  • Added TLS installation wizard to the accessory installation tool.
  • Added ability to specify feed rate on final probe movements — default 0 continues to use G0; any other value uses G1 Fx where x is the configured value.
  • SD tool now allows uploading multiple files at the same time.
  • Added pending toolchange state to the toolchange wizard while already-planned lines finish their motions, and delayed wizard appearance until closer to the actual M6 command.
  • Updating the toolchange passthrough setting now updates the controller without reconnecting or reloading a file.
  • Updating the passthrough setting in Config updates that option without requiring a file reload or reconnect.
  • No longer swaps spindle min/max for grblHAL, so PWM can be used as a laser without issues.
  • pos{axis} and mpos{axis} feeder variables are now always returned in mm, regardless of report-in-inches ($13) status.
  • Homing status on connect for already-homed grblHAL devices is now more consistent.
  • Tool probe status now allows positive values — only 0 is considered unprobed.
  • Probe status badge in the tool timeline now only shows when using grblHAL with ATC=1 (tc.macro exists).
  • Added background to job progress line count for readability when the visualizer is disabled.
  • ATC options tool is now disabled if no SD card is mounted.
  • Improved reliability of Config Store truncation.
  • Added various updates to prevent the ConfigStore file (sender_rc) from becoming corrupted.
  • Corrupted ConfigStore files no longer block application startup.
  • Various firmware updates for the latest grblHAL core version.
  • Updated grblHAL profiles for the new firmware release — mostly related to laser/PWM2 behaviors.
  • Entering laser mode on grblHAL no longer swaps $30 and $31 with the laser equivalents.
  • Fixed tool timeline not reflecting the remapped tool number after minimizing.
  • Fixed issue where opening the run probe dialog with connectivity would cause all future connectivity tests to pass immediately.
  • Fixed issue where restoring an altered EEPROM value in Config without applying wouldn’t update the UI with the correct value in the Config tool.
  • Fixed toggling single-axis homing on and then off in the on-state not showing the original “go to” buttons.
  • Fixed backwards logic on the park shortcut, allowing usage when homed.
  • Fixed job progress not updating correctly after a tool change was handled via one of the wizard strategies.

As always, thanks for your continued support and feedback. If you run into anything unexpected, let us know!

Download

gSender 1.6.3 can be downloaded on Github:

https://github.com/Sienci-Labs/gsender/releases/tag/v1.6.3

gSender 1.6.2

gSender 1.6.2 is a smaller follow-up release focused on polishing up some edge-case issues that cropped up after 1.6.0, along with a number of workflow and usability improvements across the application. A lot of this work targets firmware compatibility, ATC/tool change flows, and smoothing out a few rough edges reported by the community over the last little while.

Data collection and analytics

You may also notice that gSender prompts you again about analytics/data collection preferences after updating. If this feels familiar, you may have already responded to this prompt quite a while ago and simply forgotten about it. We’ve recently changed analytics providers, so we wanted to give everyone another opportunity to review and update their preferences.

The data collected is primarily general usage metrics, operating system information, and tool usage data that helps us understand what parts of the application are being used most often and where issues may be occurring.

As always, analytics participation is completely optional and can be enabled or disabled at any time in the Config section of the application.

General Fixes and updates

  • Updated firmware defaults to better account for TLS/probe misconfiguration scenarios
  • Various firmware default updates and compatibility improvements for newer firmware versions
  • Uploading to SD cards over ethernet is working correctly again
  • Laser power slider now behaves as expected on newer firmware
  • Spindle selector now works correctly on newer firmware
  • Laser offsets now map correctly to the updated Config key structure
  • Flash utility will now automatically select grblHAL firmware when SLB_DFU is detected
  • Exiting rotary mode will once again properly restore previous machine values
  • Non-enabled spindles will no longer appear in the spindle dropdown list
  • Spindle dropdown will now attempt to refresh itself automatically if empty in the Spindle/Laser drawer

UX and Visual

  • Numerous visual and workflow improvements to the tool change wizard
New Wizard

  • Tool change wizard will now resume the spindle before returning to the previous XY position.
  • Tool change wizard and tool timeline now display annotation comments when no ATC nickname is set
Parsed Comments

  • Removed probed/unprobed status on firmware versions without a tool table
  • ATC Config will now store default values on first install instead of stored values
  • ATC Config will now warn in situations it failed to read the stored configuration file.
  • Squaring and motor tuning workflows now share the same jog popover for a more consistent experience
  • Spindle delay behaviour has been updated and is now an explicit configurable option for forced insertion when needed

Functionalities

  • Macros can now send realtime commands using the [\xNN] format
Realtime commands

Download

gSender can be downloaded on Github

https://github.com/Sienci-Labs/gsender/releases/tag/v1.6.2

gSender 1.6.1

1.6.0 was well received (thanks for all the feedback), but a few issues and edge cases popped up across different setups that we wanted to address quickly. 1.6.1 is focused on tightening things up, improving consistency, and smoothing out some rough edges.

Changes

  • Added option to skip the first tool change when using fixed strategy, with a prompt to confirm
  • Added application scaling support for larger monitors and devices (Config → Accessibility)
Widescreen – 100 percent scaling
Widescreen – 200 percent scaling
  • Rapid Position and Park buttons now enable correctly after homing on grbl controllers
  • Spindle Delay config now properly reads $392 on older firmware versions
  • Go To flyout can now move in machine coordinates (MCS) when homing is enabled
  • Go To flyout now uses the same safe height logic as other Go To actions
  • Machine defaults selector will now prompt to apply changes where needed
  • Gamepad Park shortcut now works as expected
  • Gamepad Fixed Rapid Position shortcut using stale position data
  • Macro keybinds should persist again
  • Continued improvements to rotary time estimation
  • Fixed issue where tool table was assumed as compiled in from PRB: output (not always present on some grblHAL setups)
  • Laser test now calculates max values using $30 (grbl) or $730 (grblHAL) instead of local state
  • Added iOS application icon support for better branding on handheld shortcuts
  • Added option to toggle probe type directly in the Probe drawer for quicker swapping of probe block types
  • Improvements to Automations editor (variables dropdown + general UX tweaks)
  • Added option to disable Electron power saving (allows screen blanking)
  • Lite mode toggle is now more obvious when enabled/disabled
  • Macros now show again in Remote Mode
  • Updated 3D Probe instructions to better match the selected probe type

Download

All versions of gSender can be found on Github:

https://github.com/Sienci-Labs/gsender/releases/tag/v1.6.1

gSender 1.6.0 Release

Brand new gSender wow

After several months of Edge releases, testing, and community feedback, gSender 1.6.0 is here.

This release represents a large step forward for gSender. Much of the work throughout the Edge cycle focused on building out deeper tooling workflows, expanding controller capabilities in order to support newer versions of grblHAL, and improving performance and stability across the application.

A huge thanks goes out to everyone who tested the Edge builds and provided feedback along the way — many of the improvements below came directly from that input.

Below is a look at the biggest changes that made it into 1.6.0.

Firmware Compatibility

This release expands compatibility with newer grblHAL firmware cores. Updates were made across the communication and configuration layers to better align with recent firmware changes and ensure gSender can properly take advantage of all new features in more recent grblHAL versions.

These improvements help maintain compatibility as the grblHAL ecosystem continues to evolve, allowing gSender to work more reliably with newer controller firmware, updated settings structures, and additional capabilities exposed by newer firmware releases.

Performance and Infrastructure Improvements

Several foundational improvements were made for 1.6.0:

Faster Startup Times

Startup performance has been significantly improved in this release.

A number of internal optimizations were made to the application initialization process, reducing the amount of work that needs to happen before the UI becomes usable. These changes include improvements to module loading, background initialization, and general application startup flow.

In practical terms, this means gSender launches noticeably faster, especially on systems where startup time was previously a concern.

For many users the application should now feel much more responsive when opening, getting you connected to your machine and ready to work sooner.

Build System Improvements

The internal build pipeline was updated, resulting in:

  • Faster development builds
  • Smaller packaged application size
  • Improved overall maintainability
  • Mac silicon version now provided and added signing for both Mac releases

Built-in G-code Editor

gSender now includes a built-in G-code editor for inspecting and modifying files directly inside the application.

The editor includes:

  • Syntax highlighting
  • Search functionality
  • Quick navigation to specific terms or lines
  • Basic editing and saving capabilities

The editor also acts as an additional progress indicator while running jobs, highlighting which lines have been processed.

Editor

SD Card File Management

SD card functionality has been expanded significantly.

gSender can now interact directly with files stored on the controller’s SD card for grblHAL devices. It uses yModem protocol for USB connections, and FTP when connected over ethernet.

You can:

  • View files on the SD card
  • Upload files
  • Run files
  • Delete files

Files can be uploaded using drag-and-drop or file selection, making it easy to move jobs onto the controller.

When running jobs from the SD card, gSender now displays progress feedback similar to streaming jobs directly from the application.

SD Card Tool

Automatic Tool Changer (ATC) Support

One of the largest areas of work this cycle was full ATC workflow support.

gSender now includes an integrated system for managing tools, tracking tool changes, and working with the Sienci ATC more easily.

Tool Table

A new Tool Table allows you to manage all tool-related information in one place.

You can now:

  • Store tool offsets
  • Assign nicknames to tools
  • Probe individual tools or complete racks

This makes it much easier to maintain consistent tool setups across jobs.

Tool Table – now with easier nicknames!

Tool Timeline

Tool changes during a job are now represented in a Tool Timeline, giving a clear view of when tool changes occur and which tool is currently active.

This helps users quickly understand multi-tool programs and track job progress more easily.

Tool Timeline

Tool Remapping

Tool remapping allows you to adapt a G-code file’s tool numbers to your machine setup without editing the file itself.

This is particularly helpful when:

  • CAM tool numbers don’t match rack positions
  • You want to run the same job with a different tool configuration
  • Tool racks change between jobs

Remapping can now be configured directly inside gSender before running a job.

Remap Dialog

ATC Workflow Controls

New controls were added to support day-to-day ATC operation.

You can now:

  • Load tools – both manually and using the rack
  • Unload tools – both manually and using the rack

These actions tie directly into ATC macros and make managing tool states much easier during operation.

ATC Widget

Accessory Installation Tool

To make getting started with an Automatic Tool Changer easier, gSender now includes an ATC setup tool that helps guide users through the initial configuration process.

The setup tool walks through the core steps required to configure an ATC system, including importing macro templates, defining rack size and behaviour, and writing the required configuration files to the controller’s SD card. This removes much of the manual setup that was previously required and helps ensure the necessary macros and configuration files are installed correctly.

The goal of the setup tool is to simplify the process of bringing an ATC system online, reducing the chances of configuration mistakes and making it easier for users to get up and running with automated tool changes.

We’ve already also implemented a spindle install tool, to help users with setting up their spindle accessory on arrival.

Improved Visualization

Visualization has seen several improvements in this release.

Rotary Visualization Improvements

Rotary jobs are now visualized more accurately, with fixes to geometry rendering and preview alignment. This provides a much closer representation of the final machined result.

Surfacing file no longer two straight lines

Tool-Based Visualization

Tool changes are now visually separated by colour, making it easier to follow complex multi-tool jobs directly in the visualizer. What colour represents which tool is indicated in the tool timeline.

Toolpath separation

Processed Line Display

A new option allows you to hide processed lines entirely instead of greying them out.

For long jobs this can make the preview significantly easier to read.

Improved visualization speed

Visualization parsing had significant improvments on both speed and memory usage. The end result is that users should be able to visualize larger files faster.

Benchmarks indicate about a 50% increases in visualization and a 35% reduction in memory used.

EEPROM Editor

Advanced users now have access to a new EEPROM editor.

This tool allows you to:

  • View EEPROM values
  • Modify configuration parameters
  • Search for specific settings

This replaces the older legacy firmware tool and provides a more flexible interface for working with controller settings. You can find it in the Config section of gSender.

EEPROM tool in Config

Check Mode File Validation

A new Check Mode automation feature makes it easy to validate jobs before running them.

With this option enabled, on job load, you will be prompted if you want to check. If you select yes, gSender will:

  1. Enable GRBL check mode
  2. Run the loaded file
  3. Report any errors found

This helps catch issues before starting a real job.

Additional Improvements

Alongside the major features above, this release also includes a wide range of smaller improvements and fixes.

Some highlights include:

  • Custom Ethernet ports are now supported
  • Improved outline behaviour and new outline options (Rapidless square – generate a square that ignores G0 movements and just reflect cutting movements)
  • Ethernet auto-reconnect improvements
  • Better portrait mode space usage (larger buttons!)
  • Remote mode – config is now accessible, settings are now synched between the main app and remote clients
  • Config tool performance adjustments
  • Improved job time estimates when feed overrides are active
  • Improved rotary job time estimation
  • Option to backup settings over specific time periods.
  • M0 / M1 pauses now properly display associated comments
  • Better application responsiveness on small resolutions
  • Better application responsiveness/use of space on portrait mode
  • Remote mode configuration access improvements
  • Updated library dependencies
  • Numerous bug fixes and stability improvements
  • Better Config reactivity when updating options that allow new options.
  • File associations so you can load a gcode file by double clicking it in your file explorer of choice.
  • Functions that require the machine to have been are disabled until homing is reported by the firmware for grblHAL devices.
  • Gamepad options and configuration updates – some new behaviours related to jogging.
  • A number of other behaviour and performance tweaks and fixes

Thank You

This release wouldn’t have been possible without the community members who tested the Edge builds, reported issues, and provided feedback throughout the cycle.

Your input helped shape many of the features and refinements included in 1.6.0.

As always, if you run into any issues or have ideas for improvements, we’d love to hear from you.

Download

https://github.com/Sienci-Labs/gsender/releases/tag/v1.6.0

gSender Edge 1.6.0-Edge-4

gSender 1.6.0 Edge-4 is now out, bringing a solid round of improvements, fixes, and general polish.

We’re officially in the part of the Edge cycle where the focus shifts away from big new features and toward testing, optimization, and cleanup. A lot of this release is about making things faster, smoother, and more reliable based on feedback from everyone testing Edge so far.

If you’ve been waiting to try Edge, this is a really good time to jump in. As always, reports from early testers are extremely valuable.


Visualizer parsing improvements

This release includes a major rewrite of the file parsing and visualization worker used when loading G-code files.

Performance gains:

  • ~55% faster visualization time for most files
  • ~75% faster visualization for rotary files
  • ~35% less memory usage for typical files
  • ~86% less memory usage for rotary files

What this means in practice:

  • Bigger files load faster
  • Less RAM usage while previewing
  • Much better handling of large jobs

For reference, we successfully loaded an 85 MB / 5.5 million line file, which wasn’t possible in previous versions.

Large files visualize easily

If you want the full breakdown of what changed:

https://brash-elf-7d6.notion.site/gSender-Edge-4-Visualizer-Parsing-Improvements-30979195bff08056abcaf978c3db5cee


Connection and Alarm handling flow improvements

  • Connection process is generally smoother and more reliable
  • Better handling of reconnect scenarios
  • No resets in the connection workflow
  • Should reduce Alarm 14 and error 1s on connection and clearing alarms
  • We no longer assume ethernet is always grblHAL, so fluidNC/non-vanilla grbl users connecting over ethernet should properly fallback to grbl if configured as such

Responsiveness

  • Better support for smaller screens
  • Wide-but-short resolutions (like ~13xx × 7xx) should no longer cut off UI elements
  • Fixed some Remote Mode responsiveness regressions
  • Cleaner spacing in the top bar on smaller displays

Packaging

  • Fixed slow startup on AppImage builds caused by ASAR compression
  • Continued build pipeline cleanup
  • Smaller installs overall
    • Example: Mac .app size reduced from ~550 MB → <400 MB

ATC – status updates and other

  • Probed, unprobed, and off-rack/manual states are now separate statuses
  • You can always see both offset status and manual/off-rack state when applicable
  • Tool Timeline received a visual refresh for better clarity and information layout
  • Tool nicknames are now included anywhere a tool number is shown in the UI
  • Config and Templates moves into Accessory Installation Wizard
  • Extremely professional placeholder images added to ATC Installation wizard while we wait for marketing
New timeline look

New machine profiles & grblHAL Core support

  • Updated AltMill 4×8 machine profile
  • Added support for new/remapped firmware values and keys for grblHAL Core
  • Config automatically adapts based on firmware version
  • Affects EEPROM-related areas including:
    • Restore Defaults
    • Config Tool

Outline improvements

  • Outline process improved – should be faster, should work better for all types of files. Travel direction is always consistent.
  • Added new option – Rapidless Square – which computes a bounding box of only the cutting movements (G1/G2/G3) and ignores G0.
  • Can now configure outline to use custom feed rates and G1 rather than G0 (Thanks, kieraneglin)
  • Inner islands no longer considered when generating hulls for details outline – so file outline should be more consistent overall
G0 ignored, just outline cutting motions

Config updates

  • Various logic changes to config area to improve performance
  • You should notice the population of entries and search to be more performative
  • No delay when connecting on the config page

Various improvements & fixes

  • Selecting the current jog preset now resets values back to configured defaults
  • Config imports are validated before being applied
  • Diagnostic PDF now clearly shows when disconnected data isn’t available
  • Improved Run Check on Load workflow:
    • Prompts before enabling check mode and running the file
    • Probe corner can now be changed directly in the Run Probe dialog
  • Warning shown when using a non-default corner (no more probing the wrong spot)
  • Improved grblHAL flashing UX
  • Spindle selection now updates correctly when configurations change
  • Fixed connection widget interaction issues when dropdown menus are open
  • Alarm descriptions now pulled directly from grblHAL firmware
  • Various Dark Mode polish improvements
  • Fixed diameter parsing for DeskProto rotary files (for real this time). This must be toggled on inside the config section under “Rotary Diameter offset”
  • grbl Rotary – can now pass A through natively rather than always hijack Y when rotary mode switched off. This is mostly for compatibility with fluidNC/non-standard grbl variations that natively support A axis commands.
  • Camera cube added to visualizer in surfacing and rotary surfacing tools
  • No longer show the special animation for spindle/coolant when disconnected and spindle/coolant state is indeterminate

Download

gSender Edge is beta software, so expect the occasional rough edge. You can safely install gSender and gSender Edge side-by-side.

Huge thanks to everyone testing Edge and sending feedback — it directly helps shape the final 1.6.0 release.

You can find our Edge releases on GitHub:

https://github.com/Sienci-Labs/gsender/releases/tag/v1.6.0-Edge-4

gSender Edge 1.6.0-3

gSender 1.6.0 Edge-3 now available!

gSender 1.6.0-Edge-3

gSender 1.6.0-Edge-3 is rolling out with a solid set of improvements and long requested fixes.

We are approaching the feature freeze for 1.6.0, so most remaining work before the March release will focus on stability, polish, and small behaviour adjustments. It’s likely we have one more Edge release that’ll prioritize various bugs and remaining improvements. If you have been waiting to try Edge, this is a good moment to jump in. As always, reports from early testers are extremely valuable.

This update includes several notable enhancements, including major gains in load time and improvements to remote mode.

Faster load and install times

Significant changes to the packing system and build process have produced much faster startup across all tested devices.

A load time of roughly 25 seconds or longer has been reduced to about 4. Similar improvements appear on every device, including gControl.

This has been one of the most common complaints about gSender, so we are pleased with the progress and expect further gains.

Check out the load time comparisons below:

1.5.7 on PC (~25 seconds)

Edge on PC (~5 seconds)

Edge on gControl (~7 seconds)

Installation is also noticeably faster.

Silicon Mac builds, Mac Signing, and new Electron version

We’ve updated the Electron version for packaging to the latest release, which means dropping support for earlier macOS versions. The minimum OS requirements are now as follows:

  • macOS: Monterey (v12, released 2021) and up
  • Windows: Windows 10
  • Linux:
    • Ubuntu 18.04 and newer
    • Fedora 32 and newer
    • Debian 10 and newer
  • We are building and providing both an Intel (universal) build and now a Silicon (ARM64) version of gSender for macOS. Silicon users should notice a performance improvement.
  • We are now also signing our macOS builds, so hooray! Coming soon to an app store near you!

Better portrait mode

We continue refining layout behaviour to make better use of space across different display configurations.

  • Larger, clearer buttons in portrait mode and elsewhere
  • Improved spacing and alignment
  • More adjustments planned throughout the Edge cycle
New portrait Mode sizing
New button sizing on the gControl

ATC installation tool / Accessory Installation Tool

A new guided installation tool walks users through setting up supported CNC accessories.

  • First supported workflow is ATC setup
  • Future plans include spindle, laser, and first time CNC setup guides

ATC configuration

The ATC configuration tool has been streamlined.

  • Combined and reorganized options
  • Improved flow and clarity
  • Updated interface for a smoother configuration experience
Look at all the options when it comes to ATC configuration

ATC Visualization and Tool Table

  • Updated colours to a designated set of 12 for better toolpath distinction. It’s now funky fresh
  • Tool table tool nicknames are now selectable from a database of common bits, which includes search and still the ability to type in a custom note for a specific T command.
New toolpath colours
Tool table – selectable tool database

SD and FTP support

  • FTP support added, allowing uploads over Ethernet instead of USB only
  • Simplified workflow with a single refresh/list button
  • Automatic SD mount attempts when the tool opens
  • Dark mode and portrait mode updates
  • Progress bar improvements
  • Safety checks to disable the tool when connected to grbl or grblHAL devices without Ymodem or FTP support

EEPROM and configuration improvements

  • Added support for new settings in the upcoming grblCore release
  • EEPROM tool now handles all reported EEPROM settings, not only those surfaced in Config

Rotary time estimation

Time estimation for rotary jobs is now more accurate. Travel distance calculations now correctly account for A axis rotation, bringing estimates closer to real world results. Accuracy is approaching within 10 percent, with more refinement planned.

Some of the test file results for new rotary estimation

Visualization for rotary files has also improved. DeskProto typically sets Z to the surface and stores workpiece diameter in comments. gSender now uses that information to produce correct visualizations. Most gcode viewers cannot do this without explicit diameter data, so this is a meaningful improvement.

Better Rotary Visualization

Visualization matches end results

Remote mode

  • Updated look and feel
  • Settings now sync between desktop and remote clients, ensuring consistent preferences such as jog speeds, probe type, and units

Gamepad Updates

  • Fixes to certain shortcuts on gamepad firing twice, specifically the park button and probe popup
  • Added a new feature to disable dynamic speed and use a fixed value for thumbstick jogging
  • All these changes were done by a community member. Thank you for your contribution Kesmit13!
Fixed speed mode

Various fixes and improvements

  • ATC functionality updates
  • Fixed issues where tool offset was being incorrectly zeroed out on board reset
  • $SpindleESH now sent correctly on spindle select for core firmware
  • Gamepad jogging improvements, including fixed speed jogging
  • TLO probe offsets captured mid toolpath to keep UI elements current
  • Error and Alarm descriptions populated by grblHAL firmware
  • Helper accessible across all gSender tools, not only the carve page
  • Optional prompt on program close to prevent accidental exits
  • AltMill 4X8 machine profile added
  • Now using grblHAL error and alarm descriptions throughout the application
  • AltMill ZxY plus Spindle configurations removed
  • Added probe profile for BitZero 2 probe block (thanks Krudoy)

Download

gSender Edge is beta software, so expect occasional instability. You can install both gSender and gSender Edge side by side.

Thank you to everyone testing Edge and sending feedback. Your reports help shape the final 1.6.0 release.

You can find our Edge releases on GitHub:

https://github.com/Sienci-Labs/gsender/releases/tag/v1.6.0-Edge-3

gSender v1.5.7 Release

New gSender version available

We’re excited to announce the release of gSender v1.5.7, a version focused on refining performance, fixing long-standing quirks, and adding new functionality to make your CNC workflow smoother than ever.

Check below for a full list of changes. Updates are available via Github or follow the update prompts in-app on gSender startup.

v1.5.7 Changelog

  • Fixed issue with start job shortcut not firing in some situations.
  • Park shortcut now persists between sessions.
  • Unlock button now has same logic as large Alarm unlock button for Alarm 10 and 17 where it will reset and unlock for you.
  • Corner selection hidden for Z-only probe type.
  • Squaring tool calculations for custom distances are now correct.
  • Added support for Teensy boards in recognized devices.
  • Error line reporting mismatch fixed.
  • Stopping on start event codes should now correctly clear the planner and reset the board.
  • Added cut depth validation to Surfacing tool.
  • Auto-reconnect should work for Ethernet again.
  • Added import/export functionality for gamepad profiles.
  • Homing location now shows correctly on stats page.
  • Fixed issue with terminal history order.
  • Added new config option to run check on a file when it’s loaded in.
  • Fixed issue with rapid position shortcuts not memoizing positions.
  • GRBL spindle max/min again correctly updates the eeprom on change.
  • Config search behaviour updates to be more consistent with modified flag enabled.
  • Probe shortcut no longer causes an error 2 due to stale distance modal.
  • Rapid position shortcut no longer has a stale homing location value.

Download

gSender v1.5.7 can be downloaded from Github:

https://github.com/Sienci-Labs/gsender/releases/tag/v1.5.7

gSender 1.4.0 Release – Rotary, grblHAL, Jobs Stats and More 

gSender 1.4.0 is now released, officially supporting grblHAL, rotary cutting and much much more!

The official theme for this update was fundamentals, which means improving and iterating on existing features to address any shortcomings, reliability issues, or add long requested functionalities.

As always, thank you to everyone involved in using, testing and giving feedback on Edge releases over the past 4 months. We’ve been working hard to address your feedback and are excited to bring these new features over to the general userbase!

Without further ado, let’s get into this update!

A New Spin on Carving – Rotary Support

Turning to some positive news, we’re finally bringing support for Rotary axes on both grbl and grblHAL based controllers into gSender! Whether you own the Sienci Vortex or some other rotary solution, gSender has you covered in everything you might want to do.

Once enabled in preferences, the user is able to control, probe, surface and carve using the A axis!

#image_title

We’ve also updated the visualizer to better show the final result – so you can see your A-axis carving in all it’s glory!

Pushing Your Buttons – Better Gamepad Functionality

We’ve expanded and changed how gamepad works to give the user a whole host of new options for controlling their machine.

Joysticks are now able to jog the machine along any axis with variable speeds based on how far you’re moving the joystick.

We’ve added a new MPG mode which will let the user jog in a specific direction by rotating the joystick similar to physical MPG units.

There is also new alt modifiers for gamepad buttons, letting you map multiple functionalities to a specific button. Users are also able to assign a lockout button, preventing any gamepad buttons from firing until it is unlocked again.

Finally, we’ve altered the workflow for setting up a gamepad, letting the user map an action to a button instead of the opposite. We hope this lets users set up their new controllers quickly and easily and get back to cutting.

What did I just do? In-depth Job Stats and Maintenance Reminders

We’ve greatly expanded the job stats section to give you even more information about past jobs. Not only do we now track time run per com port, there is more in-depth tracking of individual jobs and any problems encountered.

We’ve also added maintenance reminders to keep you on track for keeping your machine in tip-top shape. Reminders are set up with expected run time before needing completion, and once you’ve approached that warning you’ll start to get reminders. Maintenance reminders are entirely customizable – set up your own tasks to keep on top of anything personal to your workflow.

Some Old Favourites and New Favourites

We’ve brought back code blocks for tool change to much fanfare!

Remote mode has received a number of improvements, including workflow controls and unit selection on the remote interface on phone screen size and a QR code in-app for easier navigation on your handheld device.

We’ve also added an easier way to go to a specific location – clicking the Go To button will now let you select a incremental or absolute position to move your machine to.

Touch Wherever You Want – Multi-corner Probing

No longer a one-trick pony, gSender now supports probing off any corner of your workpiece using both standard and auto-zero touchplates!

Selecting which corner you want is as easy as clicking a button – simply press the corner selector and the probe routine will automatically update offsets to both run and set the zero correctly at the selected corner!

Technical Notes – 32 bit no longer supported

We are officially dropping support for 32bit versions of gSender. It was a hard decision but continuing to support 32bit was a security concern for several libraries we use and we can’t be shackled long term to out of date libraries without alternatives. Version 1.2.2 should continue to work fine for the small subset of users (sub 1%) that we show as using 32 bit operating systems.

Firmware options – grblHAL Firmware Support

Our first non-grbl firmware officially supported is grblHAL – an up-and-coming solution that works on a wide variety of hardware.

Firmware flavour is selectable in the connection dropdown – by default most users will continue to use grbl, but swapping controller types is a simple click away.

We’ve updated the UI in a number of places to support all the new functionality available in grblHAL – including single axis probing, ethernet connectivity and more.

USB is no longer the only way to interact with your machine using grblHAL – so we’ve added a way to connect and run jobs using ethernet, which is more reliable overall.

grblHAL is also a bit more fluid when it comes to EEPROM options – so the firmware tool has been rebuilt to dynamically support all options are reported by the firmware itself and rebuild the table so you’ll always be able to easily update your EEPROM configuration no matter which plugins you have installed.

This is just a taste of new updates we’ve added – for all the details and changes, full notes can be found below!

Release Notes

  • Added Rotary Mode
    • gSender is now able to run 2+1 axis files on grbl and 4 axis files on grblHAL
    • Visualizer updated to support 4 axis rotations
    • A-axis DRO and jogging
    • Rotary probing
  • Added grblHAL controller support
    • Connect to and run jobs as normal on any grblHAL device
    • Connect over ethernet where hardware is supported
    • New grblHAL specific firmware tool that is dynamically generated based on reported settings
    • New UI elements where appropriate to support new functionality such as single axis homing
  • Gamepad improvements
    • Restructured logic and mapping of buttons to actions
    • Add secondary functionality to buttons
    • Added joystick MPG mode
    • Added lockout button to deactivate gamepad when needed
  • Improved job time estimation
    • Significantly improved initial time estimation algorithm based on machine acceleration and max speeds
    • Mid-job estimation uses initial estimate per line for more accurate remaining duration
  • Multi-corner probing – touch off any corner using both standard and auto-zero touchplates
  • Added Go To UI button to quickly go to an absolute or relative workspace coordinate
  • Clearer distinction on planned lines vs cut lines – planned lines show up as a (customizable) yellow instead of the default cut gray
  • Remote mode improvements
    • Added QR code for easier navigation to remote address on phone
    • Added workflow controls and unit selection to remote mode UI
  • Added preference to prompt on Zero to prevent accidentally resetting zero on any axis
  • Code block toolchange again supported
  • Firmware active modals now displayed in diagnostic tab
  • PRB values available to use in macros
  • Files are now parsed once per run time
  • Fix for DRO precision in some situations
  • Improved job stats area – now tracks jobs per com port, more information about each job run and the number of problems encountered
  • Maintenance reminders – set up and customize maintenance reminders to prompt tasks after specific run time totals have occured
  • Improved alarm and error recording

Download gSender 1.4.0

As always, releases can be found on Github!

Next Big SLB Update

It’s SuperLongBoard update time!

Hi everyone, Chris here. It’s great to be speaking with y’all again, it’s not often I get around to writing blog posts since I tend to be more behind the curtain on the tech development we do here at Sienci. As Andy mentioned in his November Production Update post, there’s a lot to update on so I’ll spread as many juicy details as I can. We’re now at over 400 people interested in buying the new SLB system we’ve been working very hard at so thank you for your support! It’s very clear that our community is very excited about this massive upgrade to the LongMill and for the future of the hobby CNC industry.

To read past updates about the SLB, see our first major blog post (First look at the SuperLongBoard) as well as all the Production Updates that Andy has been putting out to keep you guys updated on our progress: May Update 1, Aug Update 2, Sept Update 3, Oct Update 4.

There’s also a video I filmed which you can feel free to watch if you prefer to see more of my face 🙂

Recap

Let’s start with a quick refresher about how the SLB came to be Sienci’s biggest project to-date.

As many of you know, Sienci Labs has historically been built up by our mechanical solutions – an expected direction seeing as myself and Andy co-founded the company while studying Mechanical Engineering. Our goal with Sienci was always to take advanced, industry technology and try to find a way to simplify it in ways that made it less expensive and easier to use so that everyone could have access to making complex things at home. We feel like that goal of price-point and ease-of-access is something we’ve been proud and successful at to-date with our big projects like the LongMill turned LongMill MK2 CNC, LaserBeam laser system, Vortex rotary axis, AutoZero touch plate, and our unique MK2 Magnetic Dust Shoe.

What’s been clear to us since the start though is that the CNC experience won’t be able to be improved with mechanics alone. Most hobby CNC communities have quirks with their machines, but once those quirks are understood the majority of confusion comes from everything else you see day-to-day when you use it: designing projects, tool selection, feeds and speeds, machine control, and reliable cutting. This is why we started working hard on non-mechanical solutions that we’re also very proud of like gSender for open-source CNC control, our in-house feeds and speeds charts, our expansive resources for learning and understanding CNC, ever-growing roster of tutorial videos, and now the SLB.

Why the SLB?

The SuperLongBoard is a next-generation CNC control board we’ve been dreaming of making for years now and is getting closer to completion. We believe that at this current stage, integrating smarter, more reliable, and more capable CNC control electronics will make the biggest improvement to the CNC experience. If you look at options on the market there’s been a large divide between the capabilities and reliability of the typical hobby CNC boards in the $40-$200 price range and the far more expensive, semi-industrial options that can reach the several-hundred-dollar range to over $1000. With chips getting more powerful and lower cost, we thought that gap in ability could be reduced while still staying in the lower price range by making a board with those new technologies. We knew this was going to be a big challenge – there are reasons why it’s typically easier to up-sell older technologies than it is to develop new ones – but we felt strongly in our decision. We felt that creating a new, improved, and unique solution could bring new innovation to the market to benefit everyone by reducing barriers to entry, keeping the industry progressing, and making more reliable and capable CNCs at lower price-points.

Working alongside Andrew and his team at Expatria Technologies, and building off of Terje Io’s amazing grblHAL project, all these tools need to work hand-in-hand so we can set our sights on resolving two major areas that we think hobby CNCs could benefit from:

  1. Reliability: this is such a broad topic to solve, but it can be more-or less divided into a couple categories.
    • Board wiring and protections: designing a board with proper grounding and plenty of voltage protection and isolation takes a lot of time and experience but is needed to shelter the electronics from CNCing – an electrically ‘noisy’ environment from all the moving motors and static electricity buildup from cutting and vacuuming materials
    • USB protocol: this is implemented in firmware and grblHAL comes with far more checks with data communication mechanisms in place to guarantee delivery over USB and know when to resend lost information
    • Backup Communications: adding Ethernet on top of grblHAL’s already robust USB implementation isn’t necessary but having an alternate communication method to turn to is always a great option if you’re ever experiencing problems with the primary style – an onboard SD card also gives you that flexibility
    • Processor speed: a slower processor can’t buffer as much information when dealing with short and complex movements, meaning better chips can reduce the chance of errors popping up
  2. Room for growth & “Wow factor”
    • Motor drivers: the same stepper motor controlled by different motor drivers can see notably better performance with all else being equal – so why not upgrade to newer-age drivers to get better speed with less motor noise out of the same CNC
    • Smarter CNC: having the CNC better tell you when something has gone wrong, automatically fix a problem for you, or make one of your existing processes easier creates far less room for error
    • More control options: there are typically specific limitations on what a CNC can do, so why not expand it’s options to support all commonly used CNC accessories plus leave space for even more customizable outputs. This can include things like independent Macros buttons, independent Spindle and Laser control, Modbus over RS485 for more closed-loop VFD control, tool length sensor support, ring and rail lights, door sensor, CANBUS, CNC pendant options to control the machine more easily, adapting to plasma cutting, and more
    • Multi-axis control: benefits those who have started to dive into cutting rotary projects to create ornate, fully 3D projects on their CNC and want either a simpler transition between cutting styles or are interested in full 4-axis cutting
    • Onboard computer: if you’ve ever run into problems with a Windows update, USB port falling asleep, or having hardware too underpowered to run your CNC, these problems can all be solved with a dedicated, purpose-built, and built-in computing solution running something like gSender onboard

We think we can address most of these aspects with the SLB at the time it ships so it can play a part of the next big step in hobby CNC technology. It’s advanced electronics and software will bring not just new features and functionality to the LongMill, but at a price point that we believe will be affordable for hobbyists. With it being a Sienci project, it can also guarantee that the SLB will be backward compatible with ALL LONGMILL CNC MACHINES OF ALL GENERATIONS, which means that users can upgrade their machine’s capabilities by simply replacing the controller. It will also support all our current plug-in add-ons. We also plan, just like with gSender, to make our board well documented and able to be adapted to many other CNC form-factors when we start to work through rolling it out in production.

How it’s coming along

Very well! Since Andy’s last update, our SLB team has been working hard to prioritize checking the functionality of the physical circuitry on the V2 prototype board are we’re now feeling confident that the following circuity is good to go:

Newest version of the SLB (V2)
  • 24V 12.5A brick power supply input with power switch (no more power over computer USB)
  • External, detachable E-stop with light, controller feedback, plus 3 customizable buttons
  • More reliable implementation of serial communication over USB-C (no drivers needed) as well as Ethernet
  • 4 higher-end, independent motor drivers rated for 2.8A RMS (TMC2660C, higher efficiency, less noise and resonance)
  • RGB Machine status LED
  • ‘Contact’ style touch plate input
  • 4 independent limit switches with two connector styles and 5V or 24V output
  • Coolant digital output set via M8 and M9 commands (5V 40mA)
  • Independent rotary axis support with dedicated limit switch
  • Tool length sensor input for easier tool changes
  • Modbus over RS485 to control spindles and other accessories with two connector styles, terminal breakout and CAT3 cable with RJ11-6C/RJ25 and supports daisy-chaining
  • Very dust resilient enclosure with quick assembly
  • Many status LEDs for troubleshooting
  • Tons of opto-coupling for optimal protection against incorrect wiring and electrical noise
  • Less heavy boards with less fragile components should lead to lower failure rate
  • Extendable RGB LED ring light and rail strip output
  • 4 customizable outputs to external circuits, controllable via M62/64/63/65, M7/M9, M8/M9, and M3/M5 (2 SSR pin shorting and 2 relay/solenoid/motor driving)
  • SD card to store onboard information and possible g-code file overflow (min 512MB)
  • Door sensor for input to pause cutting
  • Special CANBUS for pendant communication
  • Extra breakout IO to access spare MCU pins and other alternate outputs
  • ADC input for future sensor input
  • Communication connections (e.g. Rx and Tx) available for future control via external controller / pendant

These could still change a little on our way to production but I’m very confident that this will give an accurate image of what the SLB will be capable of. The gray items on the list might not be ready at the time of launch but the great news is that we have verified all their circuitry and put them on the board so all that’d be missing is a firmware update we plan to put out after shipping boards to enable those features as well.

The main items absent from the list are twofold:

  1. Firstly, though we aimed for the V2 board to be our second and last prototype, we did find some areas that we wanted to tweak. These were: changing the Spindle 0-10V output back to 5V PWM to support the new spindle we’re working on, changing the Laser PWM and Flood output circuitry to deliver a signal that’s more in-line with the previous LongBoard, tweaking the RGB LED driver buffer, fixing some onboard status LEDs that were floating, and adding some more EMI improvements. Most of these changes are quite small, but we decided that getting a V3 prototype made will help us feel confident in finalizing the design for production. This is a hard decision as it’s likely going to add another 1 month to our board release timeline, but we really wanted to be sure to support one of the key features we wanted the board to have “Independant 5V PWM and EN Spindle and Laser control set via M3, M4, M5, and S g-code commands, plus SpinDir“. The V3 design should be sent out to get made in the next week and should now lock-down the full SLB design. While we wait for it to arrive we’ll be focusing fully on testing and firmware improvements.
  2. Secondly, for those who might not have been following Andy’s production updates, we’d originally envisioned the SLB as being a system of two different parts working together. The first being the board itself, containing all of the core CNC functionality controlling motors and handling g-code, and second being an optional onboard compute module that would act to replace a computer or laptop and instead be integrated. Users could connect a keyboard, mouse, and monitor to control all functions of the machine directly through the SLB. This was very exciting to us given the considerably low price of the compute module over a computer, around $40-80 dollars plus the cost of the monitor, keyboard, and mouse, as well as the extra speed, user experience, and reliability of an onboard system.

    In our extended tests with this idea in mind, we weren’t finding the success we’d hoped in creating a seamless user experience with this solution. Despite trying many Linux kernels, drivers, GPU acceleration, and bringing many more efficiencies to gSender, the Broadcom and Rockwell-based processors used on smaller compute modules were not powerful enough to accommodate the visualization of g-code directly onboard. This also meant they didn’t have extra headroom if in the future we wanted to implement other features such as having a camera monitoring system or other sensor inputs. With many months delay trying to chip away at a resolution we decided to split the development of SLB back into its two parts; prioritize improving the baseline machine performance first so CNCers don’t have to wait any longer for the SLB to make better machines, and strip out all the on-board connectors and switch to a higher-power off-board solution that we’ll implement at a later stage. This will mean anyone could still upgrade at a later date. Higher-power Fanless PCs will cost more, from our initial budget of around $80CAD/60USD for the compute module, to somewhere around $100-$200USD depending on the specs and configuration, but would ensure a smooth and seamless experience as well as provide headroom for future applications.

    To summarize, we decided to take the concept of the onboard computer and divide and conquer on it at a later date. It would’ve been really cool to have a fully integrated system but it kept pushing our board delivery back further and we felt it would benefit everyone if we just pushed ahead on the other features that will all still bring great benefit to the CNC experience. This means that users will still need to connect their computers to the board to control their machines when the first batch of SLBs release, but should still see drastic improvement.

To-date, SLB development costs have tallied to more than $300k, making it easily our most expensive project to-date if you don’t count gSender which is I’d guess is around $500k at this point. These costs are pretty standard and have mostly come from paying salaries to do in-depth research on board infrastructure options, decisions on features that CNCers would like, designing robust PCBs, lots of custom firmware development, and testing. The new board uses a large number of components, adding to the challenge and complexity in manufacturing, but this was expected and we’re working through it. We feel confident that we’ve done something useful here and we’re excited to see the interest in the SLB on launch and continue moving development forward.

grblHAL support in gSender

Another big effort we’re having to undertake to support the SLB has been with gSender. Though grblHAL has “grbl” in the name, it might as well be a completely new firmware with all the new work that our development team has had to put in so far to make a seamless CNC control experience and UI. Since grblHAL is such a new firmware on the hobby CNC scene, it’s still growing and not widely adapted, and we want to help change that. There’s so much documentation that has already been made but there’s also a lot more we have to figure out. We’ve been working on an all-new firmware flashing utility for the new board, and had to build in a lot of modularity so gSender can be compatible with old and new boards alike

Look at an example of all these new EEPROM settings!

You can see this progress being made live, with each new gSender Edge version we’ve been releasing since the start of this year.

Enclosure

Iteration on the SLB enclosure I think is coming along well, the design is now pretty much locked in 🙂

Back in April I put out a post on our Forum with the leading design we had at the time to get peoples feedback on what they thought (https://forum.sienci.com/t/official-call-for-feedback-on-new-board-in-development/8519) and the results were positive but still mixed. I wanted to take a new approach to the enclosure design to accommodate all the new plugs without them all being exposed, as well as improve cable management on the LongMill in particular. Though many people were on board, many still expressed concern with my idea behind mounting the board to the Y-axis rail due to their fear of dust, vibration, or accommodating enclosures.

After going through way more iterations internally, this is now our revised design which I feel much more confident will suit everyone’s needs:

#image_title

The main perks of this enclosure is it’s mounting versatility and wire management. With this new setup, anything that you’d expect to have more common access to faces toward the front and all other wires can be routed out the rear. The RGB status LED will be visible through the faceplate put the panel will also be easily removable for troubleshooting or servicing. All the components on the board face upwards so everything is accessible and the board has been tested to run very cool so even in hot environments and with the bit of venting we’ve added in we expect everything to operate as normal.

Rail mounting bracket

The rail mounting is also a separate piece that can be used or not. This gives versatility to mount the SLB on any surface (rail, vertical, or horizontal) with 2 or 4 screws. We’ve already begun production of the parts and should be getting them in Nov-Dec.

E-stop Design

This is also mostly completed, just waiting for some last few checks. You’ll notice on the earlier feature list that we wanted to move away from the 3 buttons attached directly to our board. This is because there was feedback that people didn’t tend to use the existing buttons because of their fixed function, and when people mounted their board out of the way they couldn’t access the buttons anyway. We wanted to fix this by making the buttons separate and customizable, and this lead to a new E-stop design with 3 other customizable buttons integrated into it! Now you’ll have the freedom to have 3 physical buttons perform a myriad of custom functions to suit your workflow right next to your E-stop.

New E-stop design

Beta Testing progress

As we’re turning the corner on finalizing the board design and implementing our initial set of firmware features, our main goal over the next month will be: test, test, test! We’re now in Phase 2 of Beta testing where our main goal is to make sure that all our new features play nicely with each other, since we already know they work well in isolation.

We currently have 3 boards with testers and 2 dedicated machines in our own shop running CNC jobs every chance we can get and have already found unique situations that cause problems which we can now work toward resolving. This also involves comparisons between the old and new board and real-life durability and performance testing. One example is Ian’s Onefinity where his former setup used our original Longboard and with the SLB he’s seen drastically reduced noise and nearly doubled movement speeds. This hasn’t been as drastic for our other testers but we’re also already noticing some of the stability and perks that the SLB has to offer. Once the batch of V3 boards arrive, the plan will be to redistribute them as well as contact a new wave of testers to complete one final round of feedback. Some people we reach out to will be those with persistent and existing EMI and disconnection problems to see if the SLB is able to resolve those issues. At that point we expect to feel confident in the performance and features we can promise with the board that we can prepare for release.

Here’s a video from Andy’s last post of us testing the new programmable macro buttons. These allow you to program a specific code or function to 3 unique buttons, rather than just start, pause, and stop, which is hardwired into the current control board. In this case, it’s being used to move the machine to a specific position to assist with getting the machine out of the way for changing tools and materials.

Pricing and Timeline

If you’re interested in our previous evaluation on price, you can look back to Andy’s original big post under the “Pricing” header (https://sienci.com/2023/04/10/first-look-at-the-superlongboard/).

The pricing is likely to be refined as we’ve made new decisions and near production, but I think no matter how you slice it you’ll be able to expect that the SuperLongBoard will be giving you every bang for your buck.

As far as timeline, many followers of this project would know that we’ve had to push our originally anticipated late-summer, early-fall launch. We’ll be putting out another update soon on the roll-out strategy we have in mind moving forward because we want to give people a guarantee to be in line for the SLB before Christmas, so stay tuned to hear more about that. You can get a glimpse of what some of the steps will be with the roll-out in Andy’s original post as well under “What’s Next?”.

As far as ongoing project schedule, much of it has been laid out in the sections above which I’ll try to summarize here:

  • Last tweaks will be made in the next week to start a batch of V3 SLB prototypes
  • Firmware, Beta testing, and gSender support will continue over the coming month while we wait for the V3s to arrive
  • SLB Enclosure and E-stop designs should also become finalized and be ready for production in the next month or so
  • Once V3s arrive, final checks can be made to feel confident about the circuit design and begin board production
  • Phase 3 of Beta testing will continue to refine Firmware and gSender support while all other production is underway

I’d say that this means the boards won’t be ready to ship in December / Christmas and are instead more likely to be able to ship around Feb-March. The first major steps we took until June 2023 involved much of the initial product churn that we expected to see, though with delays in board prototypes and unexpected difficulty interfacing with the drivers we lost about 2 additional months. Add to that the outcome of the compute module testing meant that we had to pull out a lot of components for a full redesign between V1 and V2 and now we have to address some of the missed items between V2 and V3. This is the reality of developing such a complex product and is why we now feel much more confident with the recent testing and steps that we’ve taken that the completion of the SLB for launch is just around the corner 😀

Thanks

Thanks for sticking along for the ride on this big update, I hope it answers most of your questions on where the SLB is currently at and gets you excited about what’s to come. I expect the SLB to be very unique in it’s abilities to exceed the capabilities of many hobby CNC boards, perfect even for the DIY hobby CNCer for all it’s additional IO, and still have many more plans for it in the future. Of course it’ll be an Open-source design so hopefully all this time and effort that our team has put in will be able to return to the community and benefit other efforts toward easier CNCs.

Leave any comments you have that I missed and I’ll try to answer them. As I mentioned I don’t tend to put out updates because I’m a very slow writer but I’ll ensure to keep Andy in the loop as progress continues so he can update y’all as things keep moving forward. Just remember to read the Production Updates!

Catch ya later