The Challenges Of 3D Printing Reliable Springs

April 27, 2026 by Maya Posch 19 Comments

Springs are great, but making them out of plastic tends to come with some downsides, for fairly obvious reasons. Creating a compliant mechanism that can be 3D printed and yet which doesn’t permanently deform or wear out after a few uses is therefore a bit of a struggle. The compliant toggle mechanism that [neotoy] designed is said to have addressed those issues, with the model available on Printables for anyone to give a shake.

The model in question is a toggle, which is the commonly seen plastic or metal device that clamps down on e.g. rope or cord and requires you to push on it to have it release said clamping force. Normally these use a metal spring inside, but this version is fully 3D printable and thus forms a practical way to test this particular compliant mechanism with a variety of materials.

The internal spring is a printed spiral spring, with the example in the video printed in PETG. You can of course also print it in other materials for different durability and springiness properties. As noted in the video, PLA makes for a very poor spring material, so you probably want to skip that one.

We covered compliant mechanisms in the past for purposes like blasters, including some that you can only see under a microscope.

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Slicer Settings For “Indestructible” Battle-Bot Worthy PLA Parts

April 25, 2026 by Tyler August 15 Comments

If you follow [Maker’s Muse] on YouTube, you know he’s as passionate about robot fights these days as he is about the tools he uses to make the robots. Luckily for us, he’s still got fame as a 3D printing YouTuber, as this has given him the platform to share his trade secrets for strong, robot-combat-worthy prints.

He fights robots in a ‘plastic ant-weight’ division, which restricts not only the weight of the robot but also the materials used. Not only must they be primarily plastic, but only certain plastics are allowed: PLA is in, but engineering filaments, Nylon, and TPU are out. Since necessity is the mother of invention, this has led to strong evolutionary pressure to figure out how to print the most impact-resilient PLA parts for armor and spinners.

He’s using the latest OrcaSlicer and shares the profile as a pay-what-you-want 3MF file. It’s all about solidity: a solid part with solidly fused walls and solidly linked layers. It makes sense: if you’re going to be hammering on or with these parts, you don’t want any internal voids that could either collapse or pull open.

The infill density is obviously 100%, and you’ll want a concentric pattern — this makes it look like you’re just printing walls, but it allows you to use another trick. To make sure those walls don’t all align, creating a potential weakness, OrcaSlicer’s “alternate extra wall” will put one extra wall every second layer. The extra wall causes the infill pattern to stagger and lock together.

Also helping lock it together, he’s playing with extrusion widths, with the suggested rule-of-thumb being the line width on the walls be one-half that of the internal fill — and as wide as possible. In his case, with a 0.4 mm nozzle, that means 0.4 mm wide walls and 0.8 mm for the infill. OrcaSlicer 2.3.2 also lets you play with specific flow ratios, allowing you to overextrude only the internals for strength, without overextruding on the walls and potentially ruining dimensional accuracy. He also irons all top surfaces, but admits that that’s mostly about aesthetics. The iron may make those layers a little bit stronger, though, so why not?

Would brick layers make these parts even stronger? That’s very likely; [Maker’s Muse] mentions them in the video but does not use them because they’re not implemented in-slicer, and he wants something accessible to all. On the other hand, this post-processing script seems accessible enough for our crowd.

This video/profile is exclusively about fully-solid parts. When you want strong parts that aren’t fully solid, it looks like the answer is walls.

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Spool Roller Gets Touch Screen

April 24, 2026 by Al Williams 2 Comments

If you have a desktop 3D printer, you probably want something to hang filament spools on. [LVTRC] has a spool roller that fits the bill. It also incorporates a scale and a round touch screen. (Google Translate)

We’ve seen those round screens before, and now we wonder why we didn’t think of this. The GC9A01 display shows a progress ring and lets you save settings or calibrations to EEPROM. An Arduino Nano provides the brain, and the load cell connects to an HX711. The project is made to fit a specific printer, but it should be little trouble to adapt it to a different printer or to mount it in an external mount.

One of the calibration steps, of course, is to program the weight of an empty spool to subtract from the total weight. The device can store up to five specific profiles.

Not the biggest spool holder we’ve seen. We keep thinking that we don’t know why we want a circular screen, and then someone always drops in to show us another thing we didn’t think about.

A Look At Full Spectrum 3D Printing

April 15, 2026 by Al Williams 12 Comments

Many modern desktop 3D printers include the ability to print in multiple colors. However, this typically only works with a few colors at a time, and the more colors you can use, the higher the machine’s cost and complexity. However, a recent technique allows printers to mix new colors by overlaying thin sheets of different filaments. [YGK3D] looks at how it works in a recent video.

In the early days of 3D printing, there were several competing approaches. You could have separate extruders, each with a different color. Some designs used a single extruder and switched between different filaments on demand. Others melted different filaments together in the hot end.

One advantage of the hotends that melted different materials is that you could make different colors by adjusting the feed rates of the plastics. However, that has its own problems with maintaining flow rate, and you can’t really use multiple material types. But using single or multiple hotends that take one filament at a time means you can only handle as many colors as you have filaments. You can’t mix, say, white and black to get gray.

Using Full Spectrum, you can define virtual filaments, and the software figures out how to approximate the color you want by using thin layers of different colors. The results are amazing. While this technically could work on any printer, in reality, a filament-switching printer will create a ton of waste to mix colors, and a single-filament machine will drive you batty manually swapping filament.

So you probably really need a tool changer and translucent plastic. You can see the difference in the test article when using opaque filament vs translucent ones. At low layer heights, four filament colors can give you 39 different colors. At more common layer heights, you may have to settle for 24 different colors.

One issue is that the top and bottom surfaces don’t color well. However, a new plugin that adds texture to the surfaces may help overcome that problem.

We looked at Full Spectrum earlier, but development continues. If you are still trying to get a handle on your filament-switching printer, we can help.

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Flattening The Exhaust Of A Laser Cutter To Save Space

April 14, 2026 by Maya Posch 9 Comments

From laser cutters to 3D printers, having an exhaust duct at the back of a machine is a very common sight. However, these tend to be rather bulky, claiming many centimeters of precious space behind a machine even if you’d want to push it right up against a wall. This issue annoyed [TheNeedleStacker] over on YouTube so much that he had a poke at solving this problem with angled exhaust ducts, all hopefully without impairing its basic function.

Smoke machine and laser for some air ducting rave vibes. (Credit: TheNeedleStacker, YouTube) — Smoke machine and laser for some air ducting rave vibes.

Although there are some online offerings for angled exhaust port extenders, these do not quite fit the required 6″ diameter. Reducing the problem to just a matter of cross section area for simplicity’s sake, that means a 19″ wide duct at a depth of 1.5″. Making sure the transition from the tube to the flat duct doesn’t become an impediment is the tricky part, so the approach here was to mostly ignore it and just make a functional prototype to get an idea of how a direct approach worked.

Installing the contraption worked out fine, and subsequent testing showed that although it seems to slightly reduce the effective airflow compared to the flex tubing, it is absolutely rad to look at with the transparent cover and some laser light to illuminate all that’s happening inside.

While some optimization work on the duct transitions can undoubtedly eke out more performance, it’s certainly not bad for a quick project.

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Your Own Tool Changer

April 13, 2026 by Al Williams 12 Comments

All the cool new 3D printers have tool-changing heads. Instead of multiplexing filament through one hot end, you simply park one hot end and pick up another. Or pick up a different tool, depending on what you need. There are many advantages to a system like that, but one disadvantage: cost. [Ultimate Tool Changer] has been working on a design for what he calls a simple, cheap changer, and it appears to be working well, as you can see in the video below.

This is one of those things that seems easy until you try to do it. He talks about a lot of the failures and dead ends along the way.

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A mechanical keyboard, transformed to look like a retro laptop with an ipad for a screen

Modular Mechanical Keyboard Transformed Into A Compact Workstation

April 6, 2026 by Julian Scheffers 1 Comment

3D printing is a staple of the hacker community. From decorative items to rugged functional parts, almost anything you can think of, can be printed. [anurag.id] shows us some classic 3D printing hacks by converting his keyboard into a compact workstation.

Like any hacker project, the initial idea is small: he decides the knob on his mechanical keyboard is boring, so he designs some alternatives. First, one “retro style” knob. Then, like any good project, the scope creep begins. He makes another knob, and another… by the end he has 6 different designs! But don’t worry, the scope can get even bigger. He decides his ipad needs a good stand on his desk–and what better place to put it than on the keyboard? Now it’s starting to look like a real little workstation. Finally, as a finishing touch, he adds some magnetically-attached wrist rests for a compact, ergonomic workstation.

Video after the break.
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