| This research establishes a control platform for continuous rapid joule heating thermal control in advanced manufacturing applications. The developed prototype utilizes a pair of graphite rollers, integrating modular actuators, precise sensors, and multifaceted components interconnected through either serial RS-485 or analog signal chains to a central National Instruments CompactRIO. Together, these elements enable effective system orchestration and thermal regulation within the range of several hundred degrees Celsius. Closed-loop PID controllers configured using empirical system identification models demonstrate robust setpoint tracking and faster rise times relative to fuzzy logic controllers in simulation case studies. The tuned PID implementation shows less than 5 percent overshoot and 5 percent steady-state error when tracking 200 degrees Celsius setpoint commands in the actual experimental system. The controller continuously modulates power input levels based on the disparity between temperature sensor data from analog inputs and predetermined targets. Insights into the intricate transient relationships are derived from firstprinciples grey-box system modeling, guiding controller synthesis using MATLAB®tools. The front-end interface acquires rich feedback on process critical parameters like flow rates, current distribution, voltages, device states, and most critically, graphite roller surface temperatures while the back-end seamlessly coordinates automated sequential control actions through RS-485/Modbus communication. In conclusion, the integrated solution showcases an instrumentation and control approach to transition specialized rapid joule heating setups towards continuous process compatibility. This enhances flexibility for small-scale advanced manufacturing systems over conventional start-stop, batch-based electric field-assisted platforms. The research thus provides a stepping stone towards unlocking efficiency and product customizability improvements in advanced manufacturing through inventive thermal control techniques. |