Investigating The Health Impacts Of UFPs And VOCs From FDM Printers

May 20, 2026 by Maya Posch No comments

FDM 3D printing is fairly messy on a molecular scale, with the filament being heated up to temperatures high enough to melt it, which produces ultra-fine particles (UFPs) and volatile organic compounds (VOCs) in addition to the new plastic item on the build plate. Recently [Simon Pow] got somewhat worried about this pollution considering that he spends a considerable amount of time in the same room as FDM printers, sharing air.

While there is a lot of context within the topic, it’s notable that even ‘low risk’ PLA already emits formaldehyde, a group 1 carcinogen. Studies like this 2022 one by [Taehun Kim] et al. on formaldehyde, PM10 and PM2.5 show that common filaments like PLA, ABS and TPU score pretty bad here, even compared to the often maligned resin printing, also in the study. Having good ventilation in a room helps a lot, but it doesn’t reduce the levels to zero.

As noted by [Simon], PETG is much better in the VOC area, while TPU emits siloxanes, some of which are dangerous but most are considered harmless. Once you hit nylon (e.g. PA6), you’re adding caprolactam, which is mildly toxic but mostly just an irritant. Where things get serious is with ABS and ASA, when you add styrene to the mix. This substance is very dangerous, being toxic, mutagenic and possibly carcinogenic, but on the plus side it smells kind of sweet.

Polycarbonate (PC) emits BPA, with its worrying long-term health implications, while carbon fibers in particular can have asbestos-like long-term effects, as we covered previously. Definitely wear PPE while doing things like sanding CF parts and safely dispose of any debris.

Of course, you can do something about this problem, such as having an enclosure around the printer, with HEPA filtration and activated carbon, potentially exhausting into the outside air. The options here are covered in the video, including a BentoBox filter. For [Simon] the biggest improvement – as measured by a whole room sensor – came from a big fan in the window, while the default activated carbon filter in the Bambu Lab printer did effectively nothing.

The problem here is mostly one of long-term exposure, so even basic precautions like filtration and ventilation can already make all the difference. Ideally you’d not have the printer in the same room as where you work, of course, but adding a good filtration setup doesn’t have to be expensive or hard.

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Two printed circuit boards made from 3D prints and copper foil. One white and one black substrate.

Using 3D Printers To Make Circuit Boards

May 19, 2026 by Julian Scheffers 42 Comments

Custom printed circuit boards have become more and more accessible to the average hobbyist over the last decade. But one problem still remains: your circuits will take at least a couple days to make. But what if you needed some really rapid prototypes? [The Raccoon Lab] shows us how to do it with a 3D printer.

You start with the usual hobby PCB pipeline: take your idea, make a schematic, and then lay it out in KiCad. That’s where the changes start: to keep traces strong, they are made very thick. The PCB is then exported and opened in 3D CAD software, where the traces are extruded to be 2 mm tall. Off to the printer! The newly printed “circuit board” is made conductive by applying copper tape to it, and traces are cut out along their raised edges.

The result is a very quick and dirty PCB. Sure, it isn’t exactly production-ready, but for just about any simple microcontroller project it’ll do just fine, and it’s a whole lot more accessible than milling one using a CNC! We’ve seen a few variations on this approach recently, including some custom software designed to help along the process.
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PreFlight Slicer Brings Added Part Strength Feature, And Many More

May 15, 2026 by Donald Papp 38 Comments

Interested in taking some wild new 3D printing features for a test drive? preFlight is a free and open source slicer that brings a host of processing improvements as well as fascinating new features and interesting twists on old ones. There are almost too many to list, so here are a few that caught our eye.

Cross-sectional view of *Interlocking Perimeters*, which increases Z-strength. Unlike brick layers, layer height stays constant.

Want to mix and match different support types on the same object? No problem. How about use Nip & Tuck seams to better hide where layers start and stop? You can emboss images directly onto print surfaces with a real-time preview and use smart bridging for counter-bored holes. We particularly like the ability to preview a sliced object from the side instead of just by layer. That’s not all, either.

Those features alone are pretty intriguing, but there’s one in particular that is particularly relevant to creating stronger parts. Interlocking Perimeters increases layer bonding to increase object strength. Unlike brick layers, which staggers layers vertically, interlocking perimeters plays with spacing and compression to increase bonding in the Z axis while keeping layer heights constant. This is possible thanks in part to the greater control offered by Athena, the new perimeter generator.

There are plenty more features — like a full Python runtime embedded directly into the slicing pipeline, and a host of export pathways — so check out the GitHub repository for added detail and let us know in the comments if you give it a try.

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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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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This Week In Security: Flatpak Fixes, Android Malware, And SCADA Was IOT Before IOT Was Cool

April 10, 2026 by Mike Kershaw 10 Comments

Rowhammer attacks have been around since 2014, and mitigations are in place in most modern systems, but the team at gddr6.fail has found ways to apply the attack to current-generation GPUs.

Rowhammer attacks attach the electrical characteristics of RAM, using manipulation of the contents of RAM to cause changes in the contents of adjacent memory cells. Bit values are just voltage levels, after all, and if a little charge leaks across from one row to the next, you can potentially pull a bit high by writing repeatedly to its physical neighbors.

The attack was used to allow privilege escalation by manipulating the RAM defining the user data, and later, to allow reading and manipulation of any page in ram by modifying the system page table that maps memory and memory permissions. By 2015 researchers refined the attack to run in pure JavaScript against browsers, and in 2016 mobile devices were shown to be vulnerable. Mitigations have been put in place in physical memory design, CPU design, and in software. However, new attack vectors are still discovered regularly, with DDR4 and DDR5 RAM as well as AMD and RISC-V CPUs being vulnerable.

The GDDR6-Fail attack targets the video ram of modern graphics cards, and is able to trigger similar vulnerabilities in the graphics card itself, culminating in accessing and changing the memory of the PC via the PCI bus and bypassing protections.

For users who fear they are at risk — most likely larger AI customers or shared hosting environments where the code running on the GPU may belong to untrusted users — enabling error correcting (ECC) mode in the GPU reduces the amount of available RAM, but adds protection by performing checksums on the memory to detect corruption or bit flipping. For the average home user, your mileage may vary – there’s certainly easier ways to execute arbitrary code on your PC – like whatever application is running graphics in the first place!

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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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