Engineering a Next-Gen Software Architecture for IPG Tape Dispensers

Based on the IPG’s early hardware concepts, Yalantis started implementing the basic device functionality for an electric water-activated tape dispenser. This included:

• Precise motor control
• Tape feeding logic
• Cutting mechanisms – as the client delivered new hardware iterations and changed components, our engineers continuously adapted the firmware logic to support the hardware testing process.

The device architecture required two microcontrollers: a primary MCU for system logic and a secondary MCU for keypad input. To make firmware updates fast and reliable across both controllers during the active R&D phase, we implemented a custom bootloader. This allowed safe and efficient firmware flashing for developer kits and future production models.

Working in parallel with the client’s hardware engineers, Yalantis refined the embedded software to handle real-world operational issues. The system was programmed to:

• Detect and report hardware errors (such as tape jams) in real time
• Allow safe tape reversal and controlled stops
• Integrate smoothly with hardware interlocks and thermal protection mechanisms

Throughout the project, Yalantis worked in short iterations with weekly feature releases. The client team brought deep industry and hardware expertise, while Yalantis supported them with software architectural guidance. Instead of writing throwaway code for a single prototype, we structured the software as a modular platform. This ensures that the core codebase can be easily extended and reused for multiple future product lines without starting from scratch.