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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Teaching Math With 3D Printers

October 25, 2025 by Al Williams 10 Comments

We’ve often thought that 3D printers make excellent school projects. No matter what a student’s interests are: art, software, electronics, robotics, chemistry, or physics, there’s something for everyone. A recent blog post from [Prusa Research] shows how Johannes Kepler University is using 3D printing to teach math. You can see a video with Professor [Zsolt Lavicza] explaining their vision below.

Instead of relying on abstract 3D shapes projected on a 2D screen, GeoGebra, educational math software, creates shapes that you can produce on a 3D printer. Students can physically handle and observe these shapes in the real world instead of on a flat screen.

One example of how the 3D printer finds use in a math class is producing “Genius Square,” a multilevel tic-tac-toe game. You can find the model for that and other designs used in the classes, on Printables. Some prints are like puzzles where students assemble shapes from pieces.

Putting 3D printers in school isn’t a new idea, of course. However, machines have become much simpler to use in recent years, so maybe the time is now. If you can’t find money for printers in school, you can always teach robotics using some low-tech methods.

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Automatically Serving Up Canned Cat Food

October 23, 2025 by Bryan Cockfield 18 Comments

If there’s any one benefit to having a cat as a pet instead of a dog, it’s that they’re a bit more independent and able to care for themselves for many days without human intervention. The only thing that’s really needed is a way to make sure they get food and water at regular intervals, but there are plenty of off-the-shelf options for these tasks. Assuming your cat can be fed dry food, that is. [Ben Heck]’s cat has a health problem that requires a special canned wet food, and since there aren’t automatic feeders for this he built his own cat-feeding robot.

Unlike dry food that can dispense a measured amount from a hopper full of food, the wet food needs to be opened and dispensed every day. To accomplish this, his robot has a mechanism that slowly slides a wedge under the pull tab on the can, punctures the can with it, and then pulls it back to remove the lid. From there the food is ejected from the feeder down a ramp to a waiting (and sometimes startled) cat. The cans are loaded into 3D-printed cartridges and then stacked into the machine on top of each other, so the machine can dispense food cans until it runs out. This design has space for six cans.

Although there are many benefits to having pets of any sort, one of the fun side quests of pet ownership is building fun things for them to enjoy or to make caring for them easier. We even had an entire Hackaday contest based on this premise. And, if biological life forms aren’t your cup of tea, there are always virtual pets to care for as well.

Thanks to [Michael C] for the tip!

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Tinkercad In Color

October 22, 2025 by Al Williams 4 Comments

Tinkercad is famous for having lots of colors in the interface. But once you export an STL, that file is notoriously monochrome. If you are printing with a single color printer, no problems. But if you have a color printer, what do you do? [CHEP] shows some options, including a relatively new one, in the video below.

The simple way is to “paint” the STL inside your slicer. But as [CHEP] shows, that is a pain and also has some undesirable side effects. A better approach is to export each part (or, at least, each part of the same color) into separate STL files, which you can then import together in the slicer. You still have to paint, but you don’t have to select different faces, and the resulting coloring is more what you’d expect.

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Tinkercad Continues To Grow Up

October 21, 2025 by Al Williams 21 Comments

It is easy to write off Tinkercad as a kid’s toy. It is easy enough for kids to learn and it uses bright colors looking more like a video game than a CAD tool. We use a variety of CAD tools, but for something quick, sometimes Tinkercad is just the ticket. Earlier this year, Tinkercad got a sketch feature, something many other CAD programs have and, now, you can even revolve the sketch to form complex objects. Tinkercad guru [HL ModTech] shows you how in the video below.

It wasn’t long ago that we needed to cut an irregular shape out of an STL and we found the sketch feature which was perfect for that purpose. If you’ve used other CAD tools, you’ll know that sketches are typically 2D shapes that get changed into a 3D shape. The traditional thing is to simply extrude it, so if you draw a circle in 2D, you get a cylinder.

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Reverse Engineering STL Files With FreeCAD

October 21, 2025 by Al Williams 30 Comments

If you think about it, STL files are like PDF files. You usually create them using some other program, export them, and then expect them to print. But you rarely do serious editing on a PDF or an STL. But what if you don’t have anything but the STL? [The Savvy Engineer] has a method to help you if you need to reverse engineer an STL file in FreeCAD. Check it out in the video below.

The problem is, of course, that STLs are made up of numerous little triangles. The trick is to switch workbenches and create a shape from mesh. That gets you part of the way.

Once you have a shape, you can convert it to a solid. At that point, you can create a refined copy. This gives you a proper CAD file that you can export to a STEP file. From there, you can use it in FreeCAD or nearly any other CAD package you like to use.

Once you have a proper object, you can easily use it like any other solid body in your CAD program. This is one of those things you won’t need every day, but when you do need it, it’ll come in handy.

Want to up your FreeCAD game? We can help. There are other ways to hack up STL files. You can even import them into TinkerCAD to do simple things, but they still aren’t proper objects.

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CoreXY 3D Printer Has A Scissor-Lift Z-axis So It Folds Down!

October 19, 2025 by Dave Rowntree 25 Comments

We don’t know about you, but one of the biggest hassles of having a 3D printer at home or in the ‘shop is the space it takes up. Wouldn’t it be useful if you could fold it down? Well, you’re in luck because over on Hackaday.io, that’s precisely what [Malte Schrader] has achieved with their Portable CoreXY 3D printer.

The typical CoreXY design you find in the wild features a moving bed that starts at the top and moves downwards away from the XY gantry as the print progresses. The CoreXY kinematics take care of positioning the hotend in the XY plane with a pair of motors and some cunning pulley drives. Go check this out if you want to read more about that. Anyway, in this case, the bed is fixed to the base with a 3-point kinematic mount (to allow the hot end to be trammed) but is otherwise vertically immobile. That bed is AC-heated, allowing for a much smaller power supply to be fitted and reducing the annoying cooling fan noise that’s all too common with high-power bed heaters.

Both ends of the cable bundle are pivoted so it can fold flat inside the frame!

The XY gantry is mounted at each end on a pair of scissor lift mechanisms, which are belt-driven and geared together from a single stepper motor paired with a reduction gearbox. This hopefully will resolve any issues with X-axis tilting that [Malte] reports from a previous version.

The coarse tramming is handled by the bed mounts, with a hotend-mounted BLTouch further dialling it in and compensating for any bed distortion measured immediately before printing. Simple and effective.

As will be clear from the video below, the folding for storage is a natural consequence of the Z-axis mechanism, which we reckon is pretty elegant and well executed—check out those custom CNC machine Aluminium parts! When the Z-axis is folded flat for storage, the hotend part of the Bowden tube feed is mounted to a pivot, allowing it to fold down as well. They even added a pivot to the other end of the cable bundle / Bowden feed so the whole bundle folds down neatly inside the frame. Nice job!

If you want a little more detail about CoreXY kinematics, check out our handy guide. But what about the H-Bot we hear you ask? Fear not, we’re on it.