Abstract The majority of motion control systems in use today employ fixed controllers, such as PID, which are tuned for nominal system conditions. Such systems, however, suffer from performance degradation as the system dynamics vary from the nominal conditions. Furthermore, cross-coupling among axes of motion also affect the positioning accuracy in contouring, particularly as the speed increases. This paper describes adaptive control strategies to alleviate this problem by adapting controller parameters on-line to compensate for changing system dynamics. Control strategies for both minimum and nonminimum phase systems are presented including cross-coupling control between axes. Part I of two papers presents the design of the multivariate adaptive control laws with stability proofs and part II describes the implementation results for an end milling process. The control schemes presented here can be utilized for a wide range of tracking control problems.