Has FDM 3D Printing Hit Its Peak?

September 2, 2026 by Jenny List 14 Comments

Over the time Hackaday has been in existence, the art of 3D printing has evolved from a relatively crude hit-and-miss affair to something approaching what we all imagined back then. You can’t yet walk up to a Star Trek replicator and ask for a part, but a modern state of the art consumer or prosumer grade printer will deliver consistent high-resolution parts, and in a surprisingly short time. [The Next Layer] asks whether consumer FDM printers have now reached the point at which they’re about as good as they’re going to get, and whether other technologies hold the future.

It’s a fair point to make that the resolution of a consumer FDM printer may be close to its mechanical limit. Techniques such as input shaping and the adoption of better CoreXY mechanisms mean that prints which once might have relied on SLA can be done in FDM. Healthy competition in the marketplace has delivered high quality colour printing, with tool-changing printers being no longer solely the preserve of the professional. He uses the example of a mobile phone to make the point that new machines have less of a wow factor to deliver, as increments have become less grand.

It’s a persuasive argument, and looking at the printers around us we can see it in action. The difference in ability between a 2020-ish and a 2026 FDM printer are far smaller than those between the same time periods in the last decade. Compare a MakerBot Cupcake and an Ultimaker II, or the Ultimaker and a Prusa Mini, and each is light years ahead of the last. But the best the Mini can do is surprisingly not as far behind as you’d expect to that of their latest, or of the equivalent from Bambu Labs.

Does this means that nothing new is coming in 3D printing? Of course not. UV printing is coming through and will deliver incredible results, as will SLS printing. It’s interesting he devotes little time to SLA printing, perhaps because it’s not as easy a process as FDM. He makes the point that we’ve never had it so good, as the high-end FDM features will appear in modestly priced machines, and we have those other technologies to look forward to.

It’s an interesting discussion, and you can see it below the break.

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Hackaday Links: August 30, 2026

August 30, 2026 by Tom Nardi 12 Comments

The big news today is, of course, the successful launch and deployment of NASA’s Nancy Grace Roman Space Telescope earlier this morning. The space agency’s latest observatory lifted off at 7:26 AM Eastern from Launch Complex 39A at Kennedy Space Center aboard a SpaceX Falcon Heavy, and by 8:00 AM it was separated from the rocket’s upper stage and flying on its own.

While the sound and fury of launch is exciting, it’s just the beginning of the journey for Roman. It will take several months for the spacecraft to complete its roughly 1.5 million-kilometer trek out to Earth’s second Lagrange point (L2), where it will set up shop near — in cosmic terms, anyway — the James Webb Space Telescope (JWST). Along the way, it will switch on and test various systems and components, with its primary 300 megapixel infrared camera scheduled to power up in three weeks or so.

There’s a lot to cover about the Roman Space Telescope. Built from spy satellite spare parts donated by the National Reconnaissance Office and featuring a field of view 100 times greater than that of Hubble, its launch is widely considered to be one of the most important scientific milestones of the decade. We’ll be bringing you more about the past, present, and future of this flagship mission as it progresses.

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Laser Your Way To Smoother FDM 3D Prints

August 29, 2026 by Tyler August 24 Comments

Now, not everyone minds the characteristic layer lines you get with Filament Deposition Modeling (FDM) 3D prints, but sometimes you need a smooth surface. If so we might go for filling primer, Bondo, or maybe break out the ABS and vapor smooth. Well, [I changed a thing] has an alternate suggestion: lasers. Laser melting can smooth the walls on a print, or the top surfaces as he shows in two different videos, both embedded below. The results look roughly similar to vapor smoothing, without the chemical exposure small risk of explosion.

Of course, you need a laser to do this, and [I changed a thing] has two diode lasers mounted to the X-axis of his printer. Of the two, the top surfaces were a lot easier to get right than the wall smoothing, which makes sense. Top surfaces are right there for the laser to get at, after all, while with his laser setup [I changed a thing] needs to get at the walls obliquely. [I changed a thing] tries melting layer-by-layer as well as a few methods to get at the walls of a finished print; which works best seems to depend on the size of and geometry of the object, so it looks like this technique is as much art as science right now.

This effort is closely related to the previous work [I changed a thing] did on improving layer adhesion with laser melting. It’s also not the first time we’ve seen laser-driven print smoothing, but that project used non-planar movements to do a post-print laser pass.

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3D Printed Piano Action Faithful To The Original

August 29, 2026 by Bryan Cockfield 12 Comments

A piano’s internal mechanism for translating a key press into sound is surprisingly complicated. It has to do a lot of things simultaneously and quickly: provide precise control over velocity, ensure the hammer doesn’t press itself against the strings, ensure the hammer rebounds without accidentally hitting the strings, allow for quick, continued strikes of the strings, and dampen the string after the key is released. Not only is that a mouthful to say, it’s a tall order for a mechanical device and took (arguably) around 150 years for the idea to be refined into what most of us would recognize as a piano. But could [dovetail] do it with a 3D printer in a few weeks?

[dovetail]’s design relies on compliant mechanisms, which are solid parts that flex in specific and controlled ways to provide movement. The action took many iterations to make sure that all of the feelings of all the parts of a real piano action were accounted for in this model. Pianos have more than one key, though, so [dovetail] also had to design a modular system to piece all the keys together. The modularity extends to the piano’s electronics as well, with a set of PCBs daisy-chained together, each of which supports a set of keys. This is a hybrid piano, a style with a real action but digital sound production. Using infrared sensors allows the instrument to behave as a MIDI keyboard, but one with the goal of feeling somewhere between a digital piano and a fully analog one.

The piano was first demonstrated at Open Sauce, where a number of musicians were able to try it out. As a prototype device it still has a few rough edges that [dovetail] plans to improve upon, like changing the sensors from IR to hall effect, improving the action and using a different filament. There are some other things he has planned as well which we look forward to seeing in future videos. And, although a completely different instrument, it has a number of similarities to this action built to strike a bass drum instead.

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Casting Engine Parts From 3D Prints

August 28, 2026 by Maya Posch 28 Comments

After building a couple of internal combustion engines by milling billet aluminium stock and cringing at the absolute waste of material this created, [Camden Bowen] figured he’d give casting metal parts a shot. Of course, the key here is to create the molds for said casting, which is where you got a few options available.

Since DIY is really his thing, he also made his own kiln using cement and perlite, plus a propane burner. For the aluminium material to melt, he bought a stack of aluminium alloy wheels, as these are made of an alloy that’s actually suitable for casting. These were turned into ingots as a first step towards casting the engine parts, which among other things helps to purify the metal.

For the actual casting method he picked lost PLA, meaning the intended shape is 3D printed in PLA, then put into plaster before it’s melted out of the newly minted mold in an oven and subsequently burned out in the kiln. For the plaster [Camden] used regular Plaster of Paris, mixed with sand to give it suitable heat-resistant properties.

After some trial and error, as well as a lot of trouble burning out all the PLA, he got a usable mold and managed to eventually cast an engine cylinder with only a few imperfections. Considering just how convoluted it would have been to mill that part out of billet aluminium, it’s easy to see why commercial manufacturers are casting such parts as well.

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Hackaday Podcast Episode 384: OCR MOD Records, Magical PCBs, And The Gravity Of Space Stations

August 28, 2026 by Al Williams 1 Comment

What did Hackaday editors Elliot Williams and Al Williams read in Hackaday last week? Probably everything, but you can tune in and hear about their favorites on this week’s podcast. They heard from lots of listeners this week, and also saw DIY projects running from a 3D-printed Stirling engine, to clogs, to LEDs.

There are some over-the-top hacks like a refit for a decades-old watch to do tap-to-pay and a — for lack of a better word — a record player that optically reads MOD files. Want to emulate an iPod? Talk to Eliza? Print a hand-operated rail car? Hackaday is the place to read about it all.

The can’t miss articles included a talk from Hackaday Europe about making magical PCBs and a not-so-brief history of space stations starting in the 1800s.

Check out the links if you want to follow along, and as always, tell us what you think about this episode in the comments!

Direct download in MP3 suitable for hand-decoding.

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Eenk Provides EInk, ESP32 Powered Text Adventures

August 27, 2026 by Tyler August 18 Comments

There’s a niche genre of text adventure that’s halfway between a traditional novel and a videogame. Think Zork if it had an extra few novels worth of words of well-crafted story to go with the action. [t0mg] is a fan of such adventures, and also quite enjoys carrying around his palm-sized ESP32 powered Xteink e-ink reader, so decided to create a project to merge the two interests, called eeink.

The Xteink readers have gotten popular lately because their modest internals and size make them very affordable. Not to mention hackable, since they’re basically an ESP32-C3 e-ink dev board that comes with a nice case and battery. The X4 Pro notably comes with an ESP32-S3 which means a lot more RAM, but this project targets both that and the X3/X4 that use the C3 version. Using the C3 means working within some rather stringent limits, as Xteink didn’t spring for any PSRAM, so [t0mg] had less memory to work with than folks did in the 80s.

This project is specifically focused on adventures using the scripting language ink, and comes with its own IDE called eenky to roll your own choose your own adventure book. It’s all on GitHub under an MIT license, and if you want to see it in action there’s a demo video embedded below.

Speaking of Zork, it wasn’t just the first commercial text adventure; it brought some important technological innovations, too.

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