Rapid Fusion HQ Robot Control

Connecting...

Live Cameras

Recordings

Loading recordings...

Temperature History

Barrel Heaters

PE320
Bed
Top Off
--C
Active: --C
Standby: --C
Middle Off
--C
Active: --C
Standby: --C
Bottom Off
--C
Active: --C
Standby: --C
Nozzle Off
--C
Active: --C
Standby: --C
Bed 0 Off
--C
Active: --C
Standby: --C
Bed 1 Off
--C
Active: --C
Standby: --C
Bed 2 Off
--C
Active: --C
Standby: --C
Bed 3 Off
--C
Active: --C
Standby: --C

Heater Control

--C
!

HEATER FAULT

One or more heaters have encountered a fault:

Filter Maintenance Required

Download Temperature Data

Time Range

1 hour

Feed Hopper

Duration 5 seconds
1s 5 min
0
seconds remaining
Feed Target
!

Confirm Action

Are you sure?

Add Material

Top C
Middle C
Bottom C
Nozzle C
All Beds C

Apply Material

Choose heater state after applying temperatures:

Settings

General Settings

Display

On-Screen Keyboard

Show on-screen keyboard when tapping input fields. Disable if using a physical keyboard.

Offline Mode

Enable for aerospace or air-gapped environments. Disables update checking and hides internet-dependent features.

When enabled, the following are disabled:
  • Automatic update checking
  • ngrok remote access
  • Dropbox cloud storage
All local features continue to work normally.

Camera Settings

USB Webcams

Detect webcams connected to this computer.

No USB cameras detected. Click "Detect Cameras" to scan.

IP Cameras

No IP cameras configured yet.

Recording Storage

Storage Used 0 MB / 5000 MB

Timelapse Recording

Saved Recordings

No recordings yet

Setup Wizard

1
Connection
2
Model
3
Beds
4
I/O Config

Duet Connection

Enter the IP address of your Duet controller. This connects Apollo to your machine.

Quick Setup

One click to apply all recommended settings for your machine.

Manual Setup

Choose a model and customize each setting individually.

Bed Configuration

Configure the number of heated beds in your system.

I/O Configuration

Configure GPIO pins and heater assignments.

Robot Control

Pellet Feeding

Barrel Heaters

Bed Heaters

Summary

I/O Settings

Update GPIO mappings without running the full wizard

Robot Control

Pellet Feeding GPIO

Connection Settings

Duet Board

Pellet Feeding

Extruder Feeder

Dryer Feeder

Heater Auto-Tune

Full Barrel Tune

Single Heater Tune

Security

Local Access

Change Password

External Access

KUKA Robot Communication

Connect to KUKA robot via KUKAVARPROXY

1 Prerequisites
2 Robot Files
3 Network
4 Variables
5 Connect

Prerequisites

Before proceeding, confirm you have the following:

You will need KukavarProxy

KukavarProxy is a free open-source tool that allows reading and writing KRL variables over TCP. No paid KUKA option packages required. Just two files to download - easy setup!

View on GitHub

Robot-Side Installation

One ZIP file - download, extract, copy, done!

Complete KUKAVARPROXY Package

Contains everything needed: KukavarProxy.exe, cswsk32.ocx, and auto-start script.

Installation Steps:

  1. Extract ZIP to USB drive (keep folder name as KUKAVARPROXY)
  2. On KUKA: Switch to Expert mode (password: "kuka")
  3. Go to Start-up > Service > Minimize HMI
  4. Copy the KUKAVARPROXY folder to C:\
  5. Open folder, right-click startup.cmd > Create Shortcut
  6. Press Win+R, type shell:startup, Enter
  7. Move the shortcut into the Startup folder
  8. Do a Cold Restart of the robot controller

That's it! KukavarProxy will auto-start on every boot.

Apollo Robot Files (Optional)

Download code snippets based on your configured variables:

Files contain your configured variables. Copy to KRC:\R1\System\

KSS 8.6+ Note: If KukavarProxy won't start, KUKA's nginx.exe may be using port 7000. Open Task Manager, end the nginx process, then try again.

Network Configuration

Configure the connection to your robot:

IP of the KLI interface on your KRC4 controller (typically 172.31.1.xxx)
KUKAVARPROXY default port is 7000
Not tested
If connection fails: Open Port 7000 on KUKA
  1. On SmartPAD: Main Menu > Start-up > Network Configuration
  2. Select Advanced (or NAT tab)
  3. Click Add to create new rule
  4. Set Port: 7000
  5. Set Protocol: TCP (add another for UDP if available)
  6. Save and reboot controller if prompted

KSS 8.6+ (Windows 10 IoT): If nginx is using port 7000, open Task Manager and end the nginx.exe process before running KukavarProxy.

Variables to Monitor

Configure which KRL variables Apollo should read from the robot:

How often to read variables (100-10000ms)
Note: Variables must be declared as GLOBAL in a .dat file on the robot. The default variables (APOLLO_VAL, APOLLO_STATUS) are defined in APOLLO_VARS.dat.

Review & Connect

Review your configuration and connect to the robot:

Before connecting, ensure:
  • KUKAVARPROXY.exe is running on the robot controller
  • APOLLO_VARS.dat is loaded on the robot
  • Network connection is established

File Transfer

Upload program folders to KUKA controller via Windows file sharing (SMB)

SMB Connection

Disconnected

Default share name: ROBOTER

Default: KukaUser

Default: 68kuka1secpw59

Usually leave empty

Path inside share to Program folder

Upload Folder

Remote Files

Path: (not connected)
Connect to browse files

Maintenance

Filter Usage

Blow Cycles
0

Settings

History

No records yet

Software Updates

Keep your system up to date

Version

Current Version
v1.0.0

GitHub Repository

Configure access to the private repository for updates

Create at github.com/settings/tokens with 'repo' scope

System Controls

Manage the Apollo server service

Support

Report bugs and request features

Automatic Error Reporting

When enabled, JavaScript errors and crashes are automatically logged for review.

Report Statistics

0
Total Reports
0
Last 24 Hours
0
Pending

Report a Bug

Describe the issue you encountered.

Request a Feature

Suggest UI improvements or new features.

Recent Reports

No reports yet

User Guide

Learn how to use Apollo 2.5 Control Interface

Getting Started First-time setup & login
Heater Control Temperature management
Material Library Save & apply presets
Camera System Live view & recording
Pellet Feeding Hopper & feeder control
Troubleshooting Fix common issues
Quick Reference Colors & common tasks

Getting Started

Logging In

  1. Open your web browser and navigate to the Apollo UI address
  2. Enter your password on the login screen
  3. Click Login to access the dashboard
Default Password: RapidFusionPE320 (change this after first login)

First-Time Setup Wizard

For new installations, run the Setup Wizard:

  1. Click the Settings button (gear icon) in the top-right
  2. Navigate to Setup Wizard in the left sidebar
  3. Follow the 4 steps:
    1 Connection - Enter your Duet controller's IP address
    2 Model - Select your machine type (PE320, Pulsar, or Custom)
    3 Beds - Configure the number of heated beds
    4 I/O Config - Set up GPIO pins for robot pause and pellet feeders
  4. Click Save Configuration to apply settings

Dashboard Overview

Connected
Last update: 2 sec ago
Temperature History
Grid Graph
PE320 Bed 1h LIVE
Barrel Heaters
Top
248C
Mid
245C
Bot
180C
Noz
250C

Heater Control

Understanding Heater Cards

Each heater card displays real-time temperature information:

Nozzle Active
247C
Active 250C
Standby 180C
Zone Name
State Badge
Current Temperature
Target Temperatures
Off 23C
Standby 180C
Active 247C
Fault --C

Adjusting a Heater

Click any heater card to open the editor:

Nozzle
247C
250
180
Click a heater card to open this editor

Emergency Controls

Turn All Heaters Off - Immediately disables all barrel and bed heaters. Use in emergency situations.
Pause Robot Program - Sends a GPIO signal to pause the robot. Requires proper I/O configuration in Setup Wizard.

Clearing Heater Faults

When a heater enters Fault state:

  1. A fault modal will appear showing affected heaters
  2. Click Clear Fault next to each heater
  3. The heater returns to Off state
  4. Investigate the cause before reactivating

Temperature Graph

Graph Controls

PE320 / Bed Switch between barrel and bed heaters
1h Change time window (1-24 hours via slider)
< LIVE > Navigate through time or return to live view
CSV Download temperature data as CSV file

Interacting with the Graph

  • Hover over the graph to see exact temperatures at any point
  • Click legend items to show/hide individual heater lines
  • Fullscreen - Click the expand button for a larger view

Material Library

What is the Material Library?

The Material Library stores temperature presets for different materials. Create presets once and apply them with one click.

Adding a New Material

  1. Click the + Add Material card
  2. Enter the material name (e.g., "PLA", "PETG", "ABS")
  3. Fill in temperatures for each zone:
    Top Middle Bottom Nozzle Bed
  4. Click Save

Applying Material Temperatures

PETG Custom
Top 240
Mid 235
Bot 230
Noz 245
Bed 80
Apply Temperatures
PETG
Click "Apply Temperatures" to choose state

Camera System

Opening Camera View

Click the Cameras button in the status bar to open the full-screen camera overlay.

Camera Tile Controls

Front Camera 24 FPS
Live Preview
Snapshot
Record Video
Timelapse
Refresh

Recording & Timelapse

  • Video Recording - Up to 5 minutes per clip
  • Timelapse - Frames captured at configurable intervals
  • Snapshots - Instant image capture
Click Recordings in the camera overlay to view all saved media.

Bandwidth Mode

Toggle between Normal and Low BW modes using the WiFi icon button in the camera overlay header.

Normal Mode Full frame rate (up to 30 FPS), higher quality streams. Best for local network or fast connections.
Low BW Mode Reduced frame rate (5-10 FPS), lower resolution. Use for slow connections, remote access, or when multiple cameras cause lag.
If cameras appear choppy or freeze frequently, try enabling Low Bandwidth mode.

Pellet Feeding

Using the Feed Dialog

  1. Click Feed Hopper to open the pellet feeder control
  2. Set Duration using the slider (1 second to 5 minutes)
  3. Select Target:
    • Dryer - Feed pellets to dryer hopper
    • Extruder - Feed pellets directly to extruder
  4. Click Start Feed
  5. To cancel, click Stop Feed at any time
Pellet feeding requires proper GPIO configuration in Settings > I/O

Remote Access

What is Remote Access?

Remote access uses ngrok to create a secure tunnel, allowing you to control your machine from anywhere with an internet connection - even outside your local network.

Enabling Remote Access

  1. Go to Settings > Remote Access
  2. Enter your ngrok Auth Token (get one free at ngrok.com)
  3. Optionally set a custom Domain for a permanent URL
  4. Toggle Enable ngrok to On
  5. Your remote URL will appear once connected

Security Considerations

Important: Remote access exposes your machine to the internet. Always use a strong password and consider enabling authentication for all connections.
  • Change the default password immediately
  • Use a custom ngrok domain for consistent access
  • Disable remote access when not needed

Maintenance

Filter Cleaning Schedule

The system tracks pellet feed cycles and reminds you when filters need cleaning. Regular maintenance prevents clogs and ensures consistent material flow.

Dryer Filter Cleaning

  1. When prompted, power off the dryer
  2. Remove and clean the filter
  3. Reinstall the filter securely
  4. Click Mark as Cleaned to reset the counter
Default cleaning interval: Every 1440 feed cycles. Adjust in Settings > Maintenance.

Extruder Cleaning

The extruder feed path should be cleaned periodically to prevent material buildup. Follow the same process as dryer cleaning when prompted.

Maintenance History

View past maintenance events in Settings > Maintenance. The history shows when each component was last cleaned and helps track maintenance patterns.

Heater Tuning

What is PID Tuning?

PID (Proportional-Integral-Derivative) tuning optimizes how heaters reach and maintain target temperatures. Proper tuning prevents overshooting, oscillation, and slow heating.

When to Run Auto-Tune

  • After replacing a heater cartridge or thermistor
  • If temperatures oscillate around the target
  • If heaters are slow to reach target
  • After significant hardware changes

Running Auto-Tune

  1. Go to Settings > Heater Tuning
  2. Select the heater zone to tune
  3. Set the target temperature (use your typical operating temp)
  4. Click Start Auto-Tune
  5. Wait for the process to complete (several minutes)
  6. New PID values are automatically saved
Do not interrupt auto-tuning once started. The heater will cycle through temperatures to calculate optimal values.

Troubleshooting

Connection Issues

The status indicator in the top-left shows your connection state:

Green - Connected

Everything is working normally. Data updates every 1-2 seconds.

Yellow - Intermittent / Slow

Connection is unstable or responses are delayed. Common causes:

  • Network congestion or weak WiFi signal
  • Duet controller is busy processing commands
  • Too many camera streams active simultaneously

Recovery steps:

  • Enable Low Bandwidth mode for cameras
  • Move closer to WiFi router or use wired Ethernet
  • Reduce number of active camera streams
Red - Disconnected

No communication with the Duet controller. Common causes:

  • Duet controller powered off or rebooting
  • Incorrect IP address configured
  • Network cable unplugged or WiFi disconnected
  • Firewall blocking communication

Recovery steps:

  • Verify Duet IP address in Settings > Connection
  • Check that Duet controller has power (status LEDs)
  • Ensure both devices are on the same network
  • Try accessing the Duet Web Control directly

Heater Faults

Common causes of heater faults:

  • Temperature sensor failure - Check thermistor wiring
  • Heater wire issue - Inspect heater cartridge connections
  • PID tuning needed - Run auto-tune in Settings > Heater Tuning

Camera Not Working

  • For USB cameras: Ensure ffmpeg is installed on the server
  • For IP cameras: Verify the stream URL is correct
  • Check that cameras are enabled in Settings > Cameras

Can't Log In

  • Default password: RapidFusionPE320
  • Password is case-sensitive - check caps lock
  • Try clearing browser cookies

Quick Reference

Status Indicator Colors

Green - Connected / Active / Success
Yellow/Orange - Warning / Standby
Red - Error / Disconnected / Fault
Gray - Off / Disabled

Common Tasks

Change heater temp Click card > Adjust slider > Click state
Apply material Material Library > Apply Temperatures > Choose state
Take snapshot Cameras > Click camera icon
Download temps Graph view > CSV > Select range > Download
Clear fault Click Clear Fault in fault popup
Feed pellets Feed Hopper > Set duration > Select target > Start

Tips

  • Use Material Presets to save time with commonly used materials
  • Monitor the Graph - temperature trends can reveal issues early
  • Follow dryer filter cleaning schedules for best performance
  • Keep software updated for bug fixes and new features
  • Use Camera Timelapse for monitoring long prints

Dev Mode

Access the full Duet Web Control interface for advanced diagnostics and configuration.

Duet Web Control

Opens the native Duet Web Control interface in a popup window. Use this for advanced configuration, G-code console, and direct machine control.

Window Closed

Alternative Access

If popups are blocked, use the button below to open in a new browser tab.

Installing Update...

Please wait...

Update Available

A new software version is ready to install.

New Version

Material Profiles

This update may include new material profiles. What would you like to do?

Your existing custom profiles will be preserved either way.

KUKA Control

Checking...

KUKA Program Manager

PATH: Uploads
Loading files...
UPLOAD PROGRAM FOLDER
Drop folder here or click to browse Supports folders, zip files, or multiple files

Control Settings

Value written to the variable when clicked
Shown as tooltip on hover