Upgrading the Creality Falcon Pro 10W with an MKS DLC32 Controller – Step-by-Step Guide

Introduction: Why I Replaced My Creality Falcon Pro Controller

My Creality Falcon Pro 10W laser was mechanically solid, but its original controller was frustratingly restrictive. While it included an ESP32 chip, Creality had disabled all Wi-Fi and Bluetooth functionality, leaving the machine isolated and USB-bound.

Trying to get it working reliably under Linux and with LightBurn was a constant struggle — serial ports failed, connections dropped, and laser power commands were inconsistent. After weeks of wasted effort, I decided to replace the factory controller entirely with an MKS DLC32 running FluidNC firmware. The result: full web-based setup, Wi-Fi G-code streaming, and total control from any device.

[Insert image: Creality Falcon Pro 10W before controller upgrade]

⚙️ Step 1: Preparing the Upgrade

Required hardware:

• MKS DLC32 board (V2.1 or newer recommended)
• 24V DC power supply (the original Falcon PSU works)
• 10W diode laser module (existing Falcon unit)
• Stepper motor connectors (X and Y motors)
• Limit switches (X and Y, if fitted)
• USB cable or Wi-Fi access

Important Note About the Compressor:
The Falcon’s original Creality controller converts 24 V DC from the PSU into 24 V AC to power the built-in compressor. The DLC32 does not provide 24 VAC output. To run the compressor after the upgrade, you will need a separate 24 V AC power supply, which is scarce but necessary.

Before disconnecting anything, take multiple photos of the Falcon’s original wiring for reference.

[Insert image: Falcon Pro factory wiring before disassembly]

⚡ Step 2: Disconnecting the Original Controller

1. Power off and unplug the Falcon completely.
2. Remove the top cover to expose the controller board.
3. Carefully label each connector: X motor, Y motor, laser, limit switches, power.
4. Unscrew the controller and set it aside.

Tip: The Creality controller uses standard pin spacing, so most plugs fit directly into the DLC32 headers with minimal modification.

🧩 Step 3: Wiring the MKS DLC32 to Falcon Pro Hardware

Use the DLC32’s labeled connectors:

⚠️ Important PWM Ground Fix:
When first connecting the diode laser to the DLC32 PWM output, I noticed the laser fan stayed on continuously, even when idle. After research, I found the DLC32 spindle output switches the ground, unlike the original Creality controller.

To fix this:

1. Disconnect the ground wire from the DLC32 PWM plug.
2. Connect the laser module ground to the DLC32 spindle ground instead.

This ensures the laser only fires when cutting, and in practice it works even better than the original Creality controller.

⚠️ Also: Make sure the PWM signal wire connects to the S (signal) pin on the DLC32; reversing it will cause incorrect firing.

[Insert image: DLC32 wiring diagram showing laser, X, Y, and power connections]

After wiring, briefly power the board and verify no motors or laser fire unexpectedly.

🧠 Step 4: Installing FluidNC Firmware via Web Interface

1. Power the DLC32 board and connect to its temporary Wi-Fi: FluidNC-xxxx, password: 12345678
2. Open a browser and go to http://192.168.0.1/
3. Choose Install Firmware → select Laser preset
4. Wait a few minutes for installation

FluidNC now boots with basic motion and laser control pre-configured.

[Insert image: FluidNC WebUI firmware installation screen]

🌐 Step 5: Configuring config.yaml

In the WebUI, click Edit Config and adjust parameters for your Falcon:

axes:
  x:
    steps_per_mm: 80
    max_travel: 400
  y:
    steps_per_mm: 80
    max_travel: 415
laser:
  pwm_hz: 1000
  tool_num: 0
switches:
  x_limit:
    pin: gpio.33
    type: limit
  y_limit:
    pin: gpio.32
    type: limit

Save and reboot — these settings are now permanent.

💥 Step 6: Why the DLC32 is a Game-Changer

Before this upgrade, LightBurn under Linux was nearly unusable:

• Serial ports failed
• Jobs randomly disconnected
• Laser commands ignored
• No network connection

The DLC32 fixed all these issues in under an hour, with full web interface control.

🔗 Step 7: Testing Laser Movement

• Open WebUI
• Jog X and Y axes to verify motion
• Use “Laser Test” at 1–5% power to confirm laser control

[Insert image: WebUI jog control interface]

🧩 Step 8: LightBurn Integration

• MKS DLC32 works flawlessly with LightBurn, including Wi-Fi control.
• Connect via USB to test:
  • Open LightBurn → Devices → Create Manually
  • Choose GRBL (ESP32)
  • Set serial port to DLC32
  • Test jogs and laser firing

Once confirmed, switch to Wi-Fi for wireless operation.

💡 Lessons Learned

• The stock Creality controller is closed and restrictive.
• Linux users face the most issues due to lack of official support.
• DLC32 + FluidNC restores full freedom: web config, Wi-Fi control, cross-platform operation.
• Important: For the original compressor, a separate 24 V AC supply is required.
• Important PWM/ground wiring: Connect the diode laser ground to the DLC32 spindle ground, not the PWM plug ground, so the laser only fires when cutting.

⚠️ Electrical Safety Disclaimer

This guide involves working with high-power DC and AC circuits inside your laser machine. Improper wiring can cause electrical shock, fire, or permanent damage to the machine.

• Always disconnect all power before touching wires.
• Verify voltage polarity before connecting to the DLC32 or laser module.
• Use proper insulated tools and take all necessary precautions.
• Follow your local electrical safety regulations.

I am not responsible for any damage, injury, or loss resulting from following this guide. Perform these upgrades at your own risk.

🏆 Conclusion

Upgrading your Creality Falcon Pro 10W to an MKS DLC32 controller gives you:

• Web-based setup via FluidNC
• Full Wi-Fi and Bluetooth control
• Cross-platform support (Linux, Windows, macOS)
• Simplified LightBurn integration
• Total control over laser parameters

This board swap transforms the Falcon from a closed system into a fully open-source laser platform — all in an afternoon.

[Insert image: Falcon Pro laser engraving after upgrade]