Does 3D-Printed Foam Make Good Custom Tires?

November 2, 2025 by Donald Papp 10 Comments

Wouldn’t it be nice to 3D print an entire custom tire for small robots? It sure would, so [Angus] of [Maker’s Muse] decided to investigate whether nifty new filaments like expanding TPU offer anything new in this area. He did more than just print out a variety of smooth tires; he tested each with a motorized platform attached to a load cell, driving on a dusty sheet of MDF to simulate the average shop floor, or ant weight combat robot arena.

Why bother making your own wheels? As [Angus] points out, when one is designing their own robots from scratch, it’s actually quite difficult to find something off the shelf that is just the right size. And even if one does find a wheel that is just right, there’s still the matter of fitting it to the shaft. Things would be so much easier if one could simply 3D print both wheel and tire in a material that performs well.

Here’s what he found: Siraya Tech’s TPU air filament (about 70A on the Shore hardness scale) performed the best. This is TPU plus a heat-activated additive that foams up during extrusion, resulting in a flexible print that looks and feels more like foam than usual TPU. It makes a promising tire that performs as well as it looks. Another expanding filament, PEBA air (also from Siraya Tech) didn’t look or perform as well, but was roughly in the same ballpark.

Both performed better than the classic DIY options of 3D-printed plain TPU, or laser-cut EVA foam. It’s certainly a lot less work than casting custom tires.

What about adding a tread pattern? [Angus] gave it a try. Perhaps unsurprisingly, a knobby tire has worse traction compared to a smooth tire on smooth MDF. But sometimes treads are appropriate, and as [Angus] points out, if one is 3D printing tires then adding treads comes at essentially zero cost. That’s a powerful ability.

Even if you are not interested in custom wheels, that foaming TPU filament looks pretty nifty. See for yourself in the video, embedded just below. If you find yourself finding a good use for it, be sure to drop us a tip!

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Learn What A Gaussian Splat Is, Then Make One

October 31, 2025 by Donald Papp 16 Comments

Gaussian Splats is a term you have likely come across, probably in relation to 3D scenery. But what are they, exactly? This blog post explains precisely that in no time at all, complete with great interactive examples and highlights of their strengths and relative weaknesses.

Gaussian splats excel at making colorful, organic subject matter look great.

Gaussian splats are a lot like point clouds, except the points are each differently-shaped “splats” of color, arranged in such a way that the resulting 3D scene looks fantastic — photorealistic, even — from any angle.

All of the real work is in the initial setup of the splats into the scene. Once that work is done, viewing is the easy part. Not only are the resulting file sizes of the scenes small, but rendering is computationally simple.

There are a few pros and cons to gaussian splats compared to 3D meshes, but in general they look stunning for any kind of colorful, organic scene. So how does one go about making or using them?

That’s where the second half of the post comes in handy. It turns out that making your own gaussian splats is simply a matter of combining high-quality photos with the right software. In that sense, it has a lot in common with photogrammetry.

Even early on, gaussian splats were notable for their high realism. And since this space has more than its share of lateral-thinkers, the novel concept of splats being neither pixels nor voxels has led some enterprising folks to try to apply the concept to 3D printing.

Nanochat Lets You Build Your Own Hackable LLM

October 20, 2025 by Donald Papp 23 Comments

Few people know LLMs (Large Language Models) as thoroughly as [Andrej Karpathy], and luckily for us all he expresses that in useful open-source projects. His latest is nanochat, which he bills as a way to create “the best ChatGPT $100 can buy”.

What is it, exactly? nanochat in a minimal and hackable software project — encapsulated in a single speedrun.sh script — for creating a simple ChatGPT clone from scratch, including web interface. The codebase is about 8,000 lines of clean, readable code with minimal dependencies, making every single part of the process accessible to be tampered with.

An accessible, end-to-end codebase for creating a simple ChatGPT clone makes every part of the process hackable.

The $100 is the cost of doing the computational grunt work of creating the model, which takes about 4 hours on a single NVIDIA 8XH100 GPU node. The result is a 1.9 billion parameter micro-model, trained on some 38 billion tokens from an open dataset. This model is, as [Andrej] describes in his announcement on X, a “little ChatGPT clone you can sort of talk to, and which can write stories/poems, answer simple questions.” A walk-through of what that whole process looks like makes it as easy as possible to get started.

Unsurprisingly, a mere $100 doesn’t create a meaningful competitor to modern commercial offerings. However, significant improvements can be had by scaling up the process. A $1,000 version (detailed here) is far more coherent and capable; able to solve simple math or coding problems and take multiple-choice tests.

[Andrej Karpathy]’s work lends itself well to modification and experimentation, and we’re sure this tool will be no exception. His past work includes a method of training a GPT-2 LLM using only pure C code, and years ago we saw his work on a character-based Recurrent Neural Network (mis)used to generate baroque music by cleverly representing MIDI events as text.

2025 Component Abuse Challenge: Conductive Filament Makes A Meltable Fuse

October 19, 2025 by Donald Papp 13 Comments

Everything is a fuse if you run enough current through it. Or at least [JohnsonFarms.us] seems to think so, which has led him to design 3D-printed fuses made from conductive PLA filament.

Conductive filament is a meltable resistor, which, if one squints hard enough, is basically a fuse.

In theory a 3D printed fuse works the same as a normal one: excessive current draw will cause the conductive plastic to briefly become a heater, causing it to self-destruct and break the electrical connection. There’s a risk of melted plastic and perhaps a nonzero combustion risk, but [JohnsonFarms.us] is less interested in whether this is a good idea and more interested in whether it can work at all, and with what degree of predictability and/or regret.

His experiments so far show that printed fuses are essentially meltable resistors with values between 300 Ω and 1250 Ω, depending on shape. What it takes to bring those to roughly 60 °C, where PLA softens, and around 150 °C, where PLA melts, is next on the to-do list.

Whatever conclusions are reached, it is interesting to think of conductive filament as a meltable resistor, and ponder what unusual applications that might allow.

Most conductive filaments have high resistance, but not all. Some, like Electrifi by Multi3D, have extremely low resistance and were used in a project that made 3d-printed logic gates.

Bit-banged 100 MBit/s Ethernet Transmission On Raspberry Pi Pico

October 18, 2025 by Donald Papp 25 Comments

The Raspberry Pi Pico is a very capable board, but it’s still a surprise to see bit-banged 100 MBit/s Fast Ethernet implemented on one. [Steve]’s Pico-100BASE-TX library allows an RP2040 (or RP2350) microcontroller to stream data at roughly 11 Mbyte/s, enough to implement 100 MBit/s Fast Ethernet transmission.

We’ve seen 10BASE-T implemented on a Pico, but it takes a lot more than just shoveling bits faster to get 100BASE-T working. 10BASE-T uses two voltage levels and Manchester encoding, but 100BASE-T uses three voltage levels, which [Steve] cleverly implemented on the Pico with two GPIOs, and far more complex encoding. Check out the repository’s README for details as well as a couple example applications.

[Steve] tells us that to the best of his knowledge, this is the first bit-banged 100 MBit/s Ethernet implementation using a microcontroller. It’s transmit-only — reception being an entirely different beast — but it’s possible some enterprising soul might find a solution. If you do, be sure to let us know all about it!

PVC Pipe Structure Design That Skips Additional Hardware

October 12, 2025 by Donald Papp 47 Comments

[Baptiste Marx] shares his take on designing emergency structures using PVC pipe in a way that requires an absolute minimum of added parts. CINTRE (French, English coverage article here) is his collection of joint designs, with examples of how they can be worked into a variety of structures.

Basic joints have many different applications.

PVC pipe is inexpensive, widely available, and can often be salvaged in useful quantities even in disaster areas because of its wide use in plumbing and as conduits in construction. It can be cut with simple tools, and once softened with heat, it can be re-formed easily.

What is really clever about [Baptiste]’s designs is that there is little need for external fasteners or hardware. Cable ties are all that’s required to provide the structural element of many things. Two sawhorse-like assemblies, combined with a flat surface, make up a table, for example.

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The Subtle Art Of Letterform Design

October 12, 2025 by Donald Papp 13 Comments

Typeface (such as Times New Roman) refers to the design that gives a set of letters, numbers, and symbols their signature “look”. Font, on the other hand, is a specific implementation of a typeface, for example, Times New Roman Italic 12 pt.

‘Q’ is a counterpoint to the idea that typography is just one fussy detail after another.

Right about this point, some of you are nodding along and perhaps thinking “oh, that’s interesting,” while the rest of you are already hovering over your browser’s Back button. If you’re one of the former, you may be interested in checking out the (sort of) interactive tour of typography design elements by the Ohno Type School, a small group that loves design.

On one hand, letters are simple and readily recognizable symbols. But at the same time, their simplicity puts a lot of weight on seemingly minor elements. Small changes can have a big visual impact. The tour lays bare answers to questions such as: What is the optimal parting of the cheeks of a capital ‘B’? At what height should the crossbar on an ‘A’ sit, and why does it look so weird if done incorrectly? And yet, the tail of a ‘Q’ can be just about anything? How and why does an ‘H’ define the spacing of the entire typeface? All these (and more) are laid bare.

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