3D Printer Turbo-Charges A Vintage Vehicle

July 4, 2025 by Seth Mabbott 16 Comments

[Ryan] of [Fat Lip Collective] has been on a streak of using 3D printing for his car mod projects. From spark plug adapters to exhaust pipes to dash panels, his CAD skills and additive manufacturing tech have played a number of roles in his process.

Most recently, [Ryan] has embarked on a mission to equip an ’80s-era Toyota KE70 Corolla with a turbo engine. The main question there being how to fit the engine back into the car once he’s inserted a salvaged turbo into the exhaust line.

There is a non-trivial amount of stuff that needs to be packed in with the rest of the engine and finding a working configuration that doesn’t get in the way of anything else requires some trial and error. Furthermore, the alignment of the many twisting and turning pieces of schedule 40 pipe that will direct gasses where they need to go needs to be pretty precise.

Juggling all of this would be tedious, time consuming, and error prone if it were not for [Ryan’s] mighty 3D printer. He printed a set of the different elbows and reducers modeled on the schedule 40 pipe that he would likely be using. He added degree markers for easy reference later and flat sections at the ends of each piece so they could be bolted to each other. With this kit of parts in hand, he was able to mock up different arrangements, re-configuring them as he considered the position of other nearby components.

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Pez Blaster Shoots Candy Dangerously Fast

July 3, 2025 by Lewin Day 3 Comments

You could use a little pocket-sized Pez dispenser if you’re a humble, reserved person. Or, you could follow the example of [Backhaul Studios], and build a dangerously powerful blaster that shoots Pez fast enough to shatter them into pieces. Just don’t aim it at your own mouth.

As the video explains, Pez is really the perfect candy for this application. It’s compact, hard, and already designed to be dispensed via a magazine. It’s thus not a big stretch to set it up to be fired out of a pistol-like blaster. The build is of the flywheel type, where a pair of counter-rotating wheels fling the candy out at great speed. The wheels themselves are spun up to high speed with a pair of small brushless motors, running off hobby speed controllers and lithium-ion batteries. A simple trigger mechanism dispenses the rectangular candies into the wheel mechanism, sending them flying out of the blaster at will. It’s all 3D-printed, designed specifically for the purpose of high-speed candy delivery.

The video goes into great detail on the design, from the development of the TPU treads on the flywheels and other details that helped improve the effectiveness of the design. The final build shoots Pez fast enough that they practically detonate upon hitting a surface.

We’ve featured some innovative work in this space from [Backhaul Studios] before—the condiment cannon was really quite something. Video after the break.

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I Gotta Print More Cowbell

July 3, 2025 by Bryan Cockfield 5 Comments

Since the earliest days of affordable, home 3D printers, the technology behind them has been continuously improving. From lowering costs, improving print quality, increasing size and detail, and diversifying the types of materials, it’s possible to get just about anything from a 3D printer today with a minimum of cost. Some of the things that printers can do now might even be surprising, like this upgrade that makes [Startup Chuck]’s 3D printer capable of printing realistic-sounding cowbells out of plastic.

The key to these metal-like prints is a filament called PPS-CF which is a carbon fiber-reinforced polyphenylene sulfide, or PPS. PPS-CF has a number of advantages over other plastics including high temperature tolerance and high dimensional stability, meaning its less likely to warp or deform even in harsh environments. But like anything with amazing upsides, there are some caveats to using this material. Not only does the carbon fiber require more durable extruder nozzles but PPS-CF also needs an extremely hot print head to extrude properly in addition to needing a heated bed. In [Startup Chuck]’s specific case he modified his print head to handle temperatures of 500°C and his print bed to around 100°C. This took a good bit of work just to supply it with enough energy to get to these temperatures and caused some other problems as well, like the magnet on the printer bed demagnetizing above around 75°C.

To get to a working cowbell took more than just printer upgrades, though. He had to go through a number of calibrations and test prints to dial in not only the ideal temperature settings of the printer but the best thicknesses for the cowbell itself so it would have that distinct metallic ring. But cowbells aren’t the only reason someone might want to print with carbon-reinforced materials. They have plenty of uses for automotive, chemical processing, high voltage, and aerospace applications and are attainable for home 3D printers. Just make sure to take some basic safety precautions first.

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Blowtorching Electroplated 3D Prints For Good Reason

June 30, 2025 by Lewin Day 27 Comments

What if you electroplated a plastic 3D print, and then melted off the plastic to leave just the metal behind? [HEN3DRIK] has been experimenting with just such a process, with some impressive results.

For this work, [HEN3DRIK] prints objects in a special PVB “casting filament” which has some useful properties. It can be smoothed with isopropanol, and it’s also intended to be burnt off when used in casting processes. Once the prints come off the printer, [HEN3DRIK] runs a vapor polishing process to improve the surface finish, and then coats the print with copper paint to make the plastic conductive on the surface. From there, the parts are electroplated with copper to create a shiny metallic surface approximately 240 micrometers thick. The final step was to blowtorch out the casting filament to leave behind just a metal shell. The only problem is that all the fire tends to leave an ugly oxide layer on the copper parts, so there’s some finishing work to be done to get them looking shiny again.

We’ve featured [HEN3DRIK]’s work before, particularly involving his creation of electroplated 3D prints with mirror finishes. That might be a great place to start your research if you’re interested in this new work. Video after the break.

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Turbine Blower 3D Prints Every Part, Including Triple Planetary Gears

June 29, 2025 by Donald Papp 18 Comments

There was a time when print-in-place moving parts were a curiosity, but [Tomek] shows that things are now at a point where a hand-cranked turbine blower with integrated planetary gears can be entirely 3D printed. Some assembly is needed, but there is no added hardware beyond the printed parts. The blower is capable of decent airflow and can probably be optimized even further. Have a look at it work in the video below.

Every piece being 3D printed brings a few advantages. Prefer the hand crank on the other side? Simply mirror everything. Want a bigger version? Just scale everything up. Because all of the fasteners are printed as well as the parts, there’s no worry about external hardware no longer fitting oversized holes after scaling things up (scaling down might run into issues with tolerances, but if you manage an extra-small version, we’d love to hear about it).

There are a few good tips that are worth keeping in mind when it comes to print-in-place assemblies with moving parts. First, changing the seam location for each layer to ‘Random’ helps make moving parts smoother. This helps prevent the formation of a seam line, which can act as a little speed bump that gets in the way of smooth movement.

The other thing that helps is lubrication. A plastic-safe lubricant like PTFE-based Super Lube is a handy thing to have around the workshop and does wonders for smoothing out the action of 3D-printed moving parts. And we can attest that rubbing candle wax on mating surfaces works pretty well in a pinch.

One downside is that the blower is noisy in operation. 3D printed gears (and even printed bearings) can be effective, but do contribute to a distinct lack of silence compared to their purpose-built versions.

Still, a device like this is a sign of how far 3D printing has come, and how it enables projects that would otherwise remain an idea in a notebook. We do love 3D-printed gears.

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BeyBlades Made Ever More Dangerous With 3D Printing

June 28, 2025 by Lewin Day 11 Comments

If you’re unfamiliar with Beyblades, they’re a simple toy. They consist of spinning tops, which are designed to “fight” in arenas by knocking each other around. While the off-the-shelf models are deemed safe enough for children to play with, [Jon Bringus] decided to take the danger level up a few notches with some custom launchers of his own design.

[Jon]’s project started with some of the early metal Beyblades, which are traditionally launched with a small geared ripcord device. He soon realized he could up the action by doing one simple thing—spinning the tops far faster than the manufacturer ever intended. More rotational speed equals more kinetic energy equals more ~~legal liability~~ fun, or so the equation goes.

The design for [Jon’s] “WMD Launcher” is straightforward enough—he combined a lawnmower pull starter with a 12:1 geartrain to turn the Beyblades at truly ludicrous speeds. It’s basic engineering — a couple of 3D-printed gears do the job — but the results are hilarious. The tops begin to emit loud noises as they turn in combat, and some move so fast and erratically that they won’t even stay inside the arena. Protective eyewear is virtually mandatory. Files are on Printables for those eager to build one at home.

Yes, ruining a game of Beyblades is as simple as building an irresponsibly fast launcher. You needn’t even use some fancy brushless motor to hurt yourself — just a little gearing is enough to cause havoc. We’ve featured similar work on this topic before, too. Video after the break.

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Building A 3D-Printed RC Dump Truck

June 27, 2025 by Lewin Day 1 Comment

Whatever your day job, many of us would love to jump behind the controls of a dump truck for a lark. In the real world, that takes training and expertise and the opportunity is denied to many of us. However, you can live out those dreams on your desk with this 3D-printed build from [ProfessorBoots.]

The build exists as two separate parts—the tractor, and the trailer. The tractor is effectively a fairly straightforward custom RC build, albeit with a few additional features to make it fit for purpose. It’s got six wheels as befitting a proper semi, and it has a nifty retractable magnetic hitch mechanism. This lets it hook up to various trailers and unhitch from them as desired, all from a press on the remote. The hitch also has provision for power and control lines that control whatever trailer happens to be attached.

As for the trailer, it’s a side-dumper that can drop its load to the left or right as desired. The dumping is controlled via a linear actuator using a small DC motor and a threaded rod. A servo controls a sliding locking mechanism which determines whether the truck dumps to the left or right as the linear actuator rises up.

The design video covers the 3D printed design as well as some great action shots of the dump truck doing its thing. We’ve featured some builds from [ProfessorBoots] before, too, like this neat 3D-printed forklift . Video after the break.

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