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Are you sure it's still an "El Cheapo" ?
Looks like a lot of work, but could probably be replicated cheaply now that all the engineering is worked out.
1 how many turns of resistances wire?
2 what kind of sensor to use for Temp. feed back?
3 where to put it?
4 what to read and control the Temp. with?
P.I.D. can be tricky when everything is home made.
I thought you were going to make your own heaters...I need to reread the post from the beginning...(Sorry I've been away a while)
I've used ADC's for years and I like them. I use the over sample method. Grab a large number of samples and average them.
I still see the need for some P.I.D. code to regulate the temperature, Or is this embedded in the 3D-printer software?