Tiggy_Wifi_Controller

cd firmware
pio run -e esp32s3-devkitc -t upload    # Tiggy Pro (6축)
pio run -e esp32s3-zero -t upload       # Tiggy Standard (3축)

tar xzf Tiggy-LinuxCNC.tar.gz
cd linuxcnc-package
chmod +x install.sh
./install.sh

📌 Supported board comparison

📌 Key features

W5500 Ethernet + WiFi auto-detection Supports both W5500 wired Ethernet and WiFi. When a W5500 module is connected, wired Ethernet is automatically preferred — no configuration needed. In CNC environments, strong electromagnetic interference (EMI) from stepper drivers, VFDs, and spindle motors can disrupt WiFi. W5500 wired Ethernet delivers real-time motion packets reliably even in these conditions.

Full 6-axis support — completely free Independent step/direction control for all 6 axes (X, Y, Z, A, B, C) at no cost. All LinuxCNC and GRBL-compatible senders get full 6-axis support for free. A Pro license for the Mach3 plugin is only required for axes 4–6.

Real-time dual-protocol (TCP + UDP) TCP port 58429 handles handshake, configuration, and commands. UDP ports 58427/58428 handle real-time motion packets and status reports. This design captures the reliability of TCP and the low latency of UDP simultaneously.

Spindle encoder feedback Spindle encoder feedback enables threading (G33/G76) and CSS — Constant Surface Speed (G96). Also supports spindle PWM (CW/CCW), coolant (flood/mist), and charge pump outputs.

Browser Web Flasher Open the Web Flasher in Chrome or Edge, connect your ESP32 via USB, select your board, and click Flash — one click, no software installation required.

📌 System architecture

📌 Hardware

All boards run the same 6-axis firmware. "Wired axes" refers to the number of step/dir GPIO pairs physically routed on the board — the firmware always supports 6 axes regardless of board.

📌 Quick start

Web Flasher (easiest):

1. Open https://michaelgaylor.github.io/Tiggy_Wifi_Controller/ in Chrome or Edge
2. Connect your ESP32 via USB and select your board
3. Click Flash — no software installation required

PlatformIO build:

cd firmware
pio run -e esp32s3-devkitc -t upload    # Tiggy Pro (6-axis)
pio run -e esp32s3-zero -t upload       # Tiggy Standard (3-axis)

LinuxCNC installation:

tar xzf Tiggy-LinuxCNC.tar.gz
cd linuxcnc-package
chmod +x install.sh
./install.sh

Mach3 installation:

1. Copy Tiggy.dll and *.pinmap to C:\Mach3\PlugIns\
2. Copy M62-M65.m1s to C:\Mach3\macros\Mach3Mill\
3. Config > Select Motion Device > Tiggy Motion Controller

📌 Role and Application of the WIZnet's Chip

Chip model: W5500

In the Tiggy WiFi Controller, W5500 is an optional wired Ethernet interface alongside WiFi. When a W5500 module is connected, it is auto-detected and used in preference to WiFi.

CNC environments generate strong electromagnetic interference from stepper drivers, spindle motors, and VFDs. This interference disrupts 2.4 GHz WiFi signals, causing real-time motion packets to drop. For operations like G33/G76 threading — which require precise synchronization of spindle RPM and axis movement — packet loss can directly ruin a workpiece.

The W5500 hardware TCP/IP stack operates reliably in these noisy environments. Because it processes TCP/IP in dedicated hardware, ESP32 CPU load is also reduced, allowing real-time step generation and network communication to run simultaneously without interference.

📌 Market and Application Value

Core markets include DIY CNC makers, home machining shops, small manufacturers, and legacy Mach3 users replacing parallel port drivers. LinuxCNC and GRBL senders support all 6 axes completely free. The Mach3 plugin provides 3-axis support for free, with a Pro license unlocking axes 4–6. The combination of open-source firmware and a commercial plugin creates a sustainable community-driven project.

📌 Summary

Tiggy WiFi CNC Motion Controller is an open-source firmware that replaces 6-axis CNC parallel ports using ESP32-S3 and WIZnet W5500 wired Ethernet (auto-detected). It supports LinuxCNC HAL, GRBL-compatible senders, and Mach3 plugin via a dual TCP+UDP real-time motion protocol. Flash instantly via browser Web Flasher. In EMI-heavy CNC environments, W5500 delivers far more stable connectivity than WiFi — a critical advantage for precision threading and synchronized motion. MIT licensed.

📌 FAQ

Q1. Which takes priority — W5500 or WiFi? If a W5500 module is connected, wired Ethernet is automatically preferred. No configuration needed.

Q2. Is full 6-axis support really free? Yes. All 6 axes are free for LinuxCNC, GRBL senders, and serial/telnet. Only the Mach3 plugin requires a Pro license for axes 4–6.

Q3. Why use both TCP and UDP at the same time? TCP handles reliable delivery for handshake, configuration, and commands. UDP handles low-latency real-time motion packets and status reports — combining the strengths of both protocols.

Q4. Which browsers does the Web Flasher support? Chrome and Edge only. The WebSerial API is required — Firefox does not currently support WebSerial.

Q5. What is spindle encoder feedback used for? Threading (G33/G76 synchronized tapping) and CSS — G96 Constant Surface Speed. It synchronizes spindle RPM with axis movement on lathes and milling machines.

Q6. Why use W5500 instead of WiFi in a CNC environment? EMI from stepper drivers, VFDs, and spindle motors interferes with 2.4 GHz WiFi. In timing-critical operations like threading, packet loss can ruin a workpiece. W5500 wired Ethernet is immune to EMI and delivers consistent real-time packet delivery.

Q7. Which G-code software is compatible? LinuxCNC (HAL component), any GRBL-compatible G-code sender (UGS, CNCjs, Candle, etc.), and Mach3 (plugin). Direct G-code input is also available via serial or telnet terminal.

Q8. What does the I/O expansion module add? Pendant buttons and relay outputs. Available with the Mach3 Pro license.

Q9. How does auto-reconnection work? On connection loss, the controller automatically attempts to reconnect. Applies to both WiFi and W5500.

Q10. What is the Protocol Tester? A Windows GUI tool for testing and configuring the controller directly without G-code software. Download from GitHub Releases.

📌 Reference links

• GitHub: https://github.com/MichaelGaylor/Tiggy_Wifi_Controller
• Web Flasher: https://michaelgaylor.github.io/Tiggy_Wifi_Controller/
• User manual: https://michaelgaylor.github.io/Tiggy_Wifi_Controller/plugin_manual.html
• Engineering reference: https://michaelgaylor.github.io/Tiggy_Wifi_Controller/engineering_reference.html
• Mach3 plugin: https://www.tiggyengineering.com