Prusa Mini with endoscope nozzle cam and pip preview

Prusa Mini Nozzle Cam On The Cheap

May 2, 2025 by Heidi Ulrich 2 Comments

Let me throw in a curveball—watching your 3D print fail in real-time is so much more satisfying when you have a crisp, up-close view of the nozzle drama. That’s exactly what [Mellow Labs] delivers in his latest DIY video: transforming a generic HD endoscope camera into a purpose-built nozzle cam for the Prusa Mini. The hack blends absurd simplicity with delightful nerdy precision, and comes with a full walkthrough, a printable mount, and just enough bad advice to make it interesting. It’s a must-see for any maker who enjoys solder fumes with their spaghetti monsters.

What makes this build uniquely brilliant is the repurposing of a common USB endoscope camera—a tool normally reserved for inspecting pipes or internal combustion engines. Instead, it’s now spying on molten plastic. The camera gets ripped from its aluminium tomb, upgraded with custom-salvaged LEDs (harvested straight from a dismembered bulb), then wrapped in makeshift heat-shrink and mounted on a custom PETG bracket. [Mellow Labs] even micro-solders in a custom connector just so the camera can be detached post-print. The mount is parametric, thanks to a community contribution.

This is exactly the sort of hacking to love—clever, scrappy, informative, and full of personality. For the tinkerers among us who like their camera mounts hot and their resistor math hotter, this build is a weekend well spent.

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A New And Weird Kind Of Typewriter

April 30, 2025 by Lewin Day 18 Comments

Typewriters aren’t really made anymore in any major quantity, since the computer kind of rained all over its inky parade. That’s not to say you can’t build one yourself though, as [Toast] did in a very creative fashion.

After being inspired by so many typewriters on YouTube, [Toast] decided they simply had to 3D print one of their own design. They decided to go in a unique direction, eschewing ink ribbons for carbon paper as the source of ink. To create a functional typewriter, they had to develop a typebar mechanism to imprint the paper, as well as a mechanism to move the paper along during typing. The weird thing is the letter selection—the typewriter doesn’t have a traditional keyboard at all. Instead, you select the letter of your choice from a rotary wheel, and then press the key vertically down into the paper. The reasoning isn’t obvious from the outset, but [Toast] explains why this came about after originally hitting a brick wall with a more traditional design.

If you’ve ever wanted to build a typewriter of your own, [Toast]’s example shows that you can have a lot of fun just by having a go and seeing where you end up. We’ve seen some other neat typewriter hacks over the years, too. Video after the break.

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A graph is shown of the percentage reflection of visible light as a function of wavelength. Four lines are traced on the graph, which all approximate the same shape. In the top left, two purple shapes are shown, which the spectral chart describes.

Paint Mixing Theory For Custom Filament Colors

April 28, 2025 by Aaron Beckendorf 11 Comments

Recycling 3D filament is a great idea in theory, and we come across homemade filament extruders with some regularity, but they do have some major downsides when it comes to colored filaments. If you try to recycle printer waste of too many different colors, you’ll probably be left with a nondescript gray or brown filament. Researchers at Western University, however, have taken advantage of this pigment mixing to create colors not found in any commercial filament (open access paper).

They started by preparing samples of 3D printed waste in eight different colors and characterizing their spectral reflectance properties with a visible-light spectrometer. They fed this information into their SpecOptiBlend program (open source, available here), which optimizes the match between a blend of filaments and a target color. The program relies on the Kubelka-Munk theory for subtractive color mixing, which is usually used to calculate the effect of mixing paints, and minimizes the difference which the human eye perceives between two colors. Once the software calculated the optimal blend, the researchers mixed the correct blend of waste plastics and extruded it as a filament which generally had a remarkably close resemblance to the target color.

In its current form, this process probably won’t be coming to consumer 3D printers anytime soon. To mix differently-colored filaments correctly, the software needs accurate measurements of their optical properties first, which requires a spectrometer. To get around this, the researchers recommend that filament manufacturers freely publish the properties of their filaments, allowing consumers to mix their filaments into any color they desire.

This reminds us of another technique that treats filaments like paint to achieve remarkable color effects. We’ve also seen a number of filament extruders before, if you’d like to try replicating this.

Improved And Open Source: Non-Planar Infill For FDM

April 23, 2025 by Heidi Ulrich 16 Comments

Strenghtening FDM prints has been discussed in detail over the last years. Solutions and results vary as each one’s desires differ. Now [TenTech] shares his latest improvements on his post-processing script that he first created around January. This script literally bends your G-code to its will – using non-planar, interlocking sine wave deformations in both infill and walls. It’s now open-source, and plugs right into your slicer of choice: PrusaSlicer, OrcaSlicer, or Bambu Studio. If you’re into pushing your print strength past the limits of layer adhesion, but his former solution wasn’t quite the fit for your printer, try this improvement.

Traditional Fused Deposition Modeling (FDM) prints break along layer lines. What makes this script exciting is that it lets you introduce alternating sine wave paths between wall loops, removing clean break points and encouraging interlayer grip. Think of it as organic layer interlocking – without switching to resin or fiber reinforcement. You can tweak amplitude, frequency, and direction per feature. In fact, the deformation even fades between solid layers, allowing smoother transitions. Structural tinkering at its finest, not just a cosmetic gimmick.

This thing comes without needing a custom slicer. No firmware mods. Just Python, a little G-code, and a lot of curious minds. [TenTech] is still looking for real-world strength tests, so if you’ve got a test rig and some engineering curiosity, this is your call to arms.

The script can be found in his Github. View his full video here , get the script and let us know your mileage!

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Jolly Wrencher Down To The Micron

April 21, 2025 by Ian Bos 6 Comments

RepRap was the origin of pushing hobby 3D printing boundaries, and here we see a RepRap scaled down to the smallest detail. [Vik Olliver] over at the RepRap blog has been working on getting a printer working printing down to the level of micron accuracy.

The printer is constructed using 3D printed flexures similar to the OpenFlexure microscope. Two flexures create the XYZ movement required for the tiny movements needed for micron level printing. While still in the stages of printing simple objects, the microscopic scale of printing is incredible.

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A 3D printer frame made of red plastic is shown on the left-hand side of the image. On the right-hand side, there is a large motor with a plastic frame attached to the frame. Next to the 3D printer, a blue plastic mesh is being fed through a red plastic frame.

The Most Printable 3D Printer Yet

April 20, 2025 by Aaron Beckendorf 17 Comments

Despite the best efforts of the RepRap community over the last twenty years, self-replicating 3D printers have remained a stubbornly elusive goal, largely due to the difficulty of printing electronics. [Brian Minnick]’s fully-printed 3D printer could eventually change that, and he’s already solved an impressive number of technical challenges in the process.

[Brian]’s first step was to make a 3D-printable motor. Instead of the more conventional stepper motors, he designed a fully 3D-printed 3-pole brushed motor. The motor coils are made from solder paste, which the printer applies using a custom syringe-based extruder. The paste is then sintered at a moderate temperature, resulting in traces with a resistivity as low as 0.001 Ω mm, low enough to make effective magnetic coils.

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Benchy, printed upside down on [Josh's] Core R-Theta printer.

Non-planar Slicing Is For The Birds

April 20, 2025 by Tyler August 15 Comments

When we say non-planar slicing is for the birds, we mean [Joshua Bird], who demonstrates the versatility of his new non-planar S4-Slicer by printing a Benchy upside down with the “Core R-Theta” printer we have featured here before.

A benchy model, upside down, with the path from the end of the prow to the printbed highlighted. — S4 slicer uses the path from any point (here, Benchy’s prow) as its basis…

This non-planar slicer is built into a Jupyter notebook, which follows a relatively simple algorithm to automatically generate non-planar toolpaths for any model. It does this by first generating a tetrahedral mesh of the model and then calculating the shortest possible path through the model from any given tetrahedron to the print bed. Even with non-planar printing, you need to print from the print-bed up (or out).

Quite a lot of math is done to use these paths to calculate a deformation mesh, and we’ll leave that to [Joshua] to explain in his video below. After applying the deformation, he slices the resulting mesh in Cura, before the G-code goes back to Jupyter to be re-transformed, restoring the shape of the original mesh.

… to generate deformed models for slicing, like this.

So yes, it is G-code bending as others have demonstrated before, but in a reproducible, streamlined, and straightforward workflow. Indeed, [Josh] credits much of the work to earlier work on the S^3-Slicer, which inspired much of the logic and the name behind his S4 slicer. (Not S4 as in “more than S^3” but S4 as a contraction of “Simplified S^3”). Once again, open source allows for incremental innovation.

It is admittedly a computationally intensive process, and [Joshua] uses a simplified model of Benchy for this demo. This seems exactly the sort of thing we’d like to burn compute power on, though.

This sort of non-planar 3D printing is an exciting frontier, one which we have covered before. We’ve seen techniques for non-planar infill, or even to print overhangs on unmodified Cartesian printers, but this is probably the first time we’ve seen Benchy given the non-planar treatment. You can try S4 slicer for yourself via GitHub, or just watch the non-planar magic in action after the break. Continue reading “Non-planar Slicing Is For The Birds” →