3d Printer hacks

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3D Print Your Own Injection Molds, Ejector Pins And All

May 5, 2025 by 20 Comments

3D printing is all well and good for prototyping, and it can even produce useful parts. If you want real strenght in plastics, though, or to produce a LOT of parts, you probably want to step up to injection molding. As it turns out, 3D printing can help in that regard, with injection molding company [APSX] has given us a look at how it printed injection molds for its APSX-PIM machine.

The concept is simple enough—additive manufacturing is great for producing parts with complex geometries, and injection molds fit very much under that banner. To demonstrate, [APSX] shows us a simple injection mold that it printed with a Formlabs Form3+ using Rigid 10K resin. The mold has good surface finish, which is crucial for injection molding nice parts. It’s also fitted with ejection pins for easy part removal after each shot of injection molded plastic. While it’s not able to hold up like a traditional metal injection mold, it’s better than you might think. [APSX] claims it got 500 automatic injection cycles out of the mold while producing real functional parts. The mold was used with the APSX-PIM injection molding machine squirting polypropylene at a cycle time of 65 seconds, producing a round part that appears to be some kind of lid or gear.

This looks great, but it’s worth noting it’s still not cheap to get into this sort of thing. On top of purchasing a Formlabs Form3+, you’ll also need the APSX-PIM V3, which currently retails for $13,500 or so. Still, if you regularly need to make 500 of something, this could be very desirable. You could get your parts quicker and stronger compared to running a farm of many 3D printers turning out the same parts.

We’ve seen similar projects along these lines before. The fact is that injections molds are complicated geometry to machine, so being able to 3D print them is highly desirable. Great minds and all that. Video after the break.

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Hacking Different Sized Nozzles For AnyCubic Printers

May 3, 2025 by 11 Comments

If you’ve got a popular 3D printer that has been on the market a good long while, you can probably get any old nozzles you want right off the shelf. If you happen to have an AnyCubic printer, though, you might find it a bit tougher. [Startup Chuck] wanted some specific sized nozzles for his rig, so set about whipping up a solution himself.

[Chuck]’s first experiments were simple enough. He wanted larger nozzles than those on sale, so he did the obvious. He took existing 0.4 mm nozzles and drilled them out with carbide PCB drills to make 0.6 mm and 0.8 mm nozzles. It’s pretty straightforward stuff, and it was a useful hack to really make the best use of the large print area on the AnyCubic Kobra 3.

But what about going the other way? [Chuck] figured out a solution for that, too. He started by punching out the 0.4 mm insert in an existing nozzle. He then figured out how to drive 0.2 mm nozzles from another printer into the nozzle body so he had a viable 0.2 mm nozzle that suited his AnyCubic machine.

The result? [Chuck] can now print tiny little things on his big AnyCubic printer without having to wait for the OEM to come out with the right nozzles. If you want to learn more about nozzles, we can help you there, too.

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Prusa Mini with endoscope nozzle cam and pip preview

Prusa Mini Nozzle Cam On The Cheap

May 2, 2025 by 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 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 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.

Non-planar 3d-print on bed

Improved And Open Source: Non-Planar Infill For FDM

April 23, 2025 by 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 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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