3d printing

842 Articles

How To Design 3D-Printed Parts With Tolerance In Mind

August 4, 2025 by 12 Comments

One of the continuing struggles with FDM printing is making sure that parts that should fit together actually do. While adding significant tolerance between parts is an option, often you want to have a friction fit or at least a gap that you cannot drive a truck through. In a video by [Slant 3D] a number of tips and tricks to improve parts design with tolerance in mind are provided.

Starting with the fairly obvious, such as avoiding sharp corners, rounding off edges and using chamfered edges  and filets for e.g. lids to make getting started easy, the video then moves into more advanced topics. Material shrinkage is a concern, which is where using thin walls instead of solid blocks of material helps, as does using an appropriate infill type. Another interesting idea is to use a compliant mechanism in the lid to get a friction fit without getting all print parameters just right.

On the opposing side to the lid – or equivalent part – you’d follow many of the same tips, with the addition of e.g. slots that allow for the part to flex somewhat. All of this helps to deal with any variability between prints, with the suggested grip fins at the end of the video being probably the most extreme.

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A variety of red and black glass objects are shown on a white background. In the foreground, there are two black spiral-patterned earrings. To the left is a red and black shape with three points on the top. On the right, a deformed glass sheet is shown bent over concentric red and black glass rings. In the center top is a red glass vase with a roughly-textured exterior.

Paste Extrusion For 3D Printing Glass And Eggshells

July 22, 2025 by 14 Comments

In contrast to the success of their molten-plastic cousins, paste extrusion 3D printers have never really attained much popularity. This is shame because, as the [Hand and Machine] research group at the University of New Mexico demonstrate, you can use them to print with some really interesting materials, including glass and eggshell. Links to the respective research papers are here: glass and eggshells, with presentations in the supplemental materials.

To print with glass, the researchers created a clay-like paste out of glass frit, methyl cellulose and xanthan gum as shear-thinning binders, and water. They used a vacuum chamber to remove bubbles, then extruded the paste from a clay 3D printer. After letting the resulting parts dry, they fired them in a kiln at approximately 750 ℃ to burn away the binder and sinter the frit. This introduced some shrinkage, but it was controllable enough to at least make decorative parts, and it might be predictable enough to make functional parts after some post-processing.

Path generation for the printer was an interesting problem; the printer couldn’t start and stop extrusion quickly, so [Hand and Machine] developed a custom slicer to generate tool paths that minimize material leakage. To avoid glass walls collapsing during firing, they also wrote another slicer to maintain constant wall thicknesses.

The process for printing with eggshell was similar: the researchers ground eggshells into a powder, mixed this with water, methyl cellulose and xanthan gum, and printed with the resulting paste. After drying, the parts didn’t need any additional processing. The major advantage of these parts is their biodegradability, as the researchers demonstrated by printing a biodegradable pot for plants. To be honest, we don’t think that this will be as useful an innovation for hackers as the glass could be, but it does demonstrate the abilities of paste extrusion.

The same team has previously used a paste printer to 3D print in metal. If you don’t have a paste printer, it’s also possible to print glass using a laser cutter, or you could always make your own paste extruder.

Double Your Printing Fun With Dual-Light 3D Printing

July 10, 2025 by 9 Comments

Using light to 3D print liquid resins is hardly a new idea. But researchers at the University of Texas at Austin want to double down on the idea. Specifically, they use a resin with different physical properties when cured using different wavelengths of light.

Natural constructions like bone and cartilage inspired the researchers. With violet light, the resin cures into a rubbery material. However, ultraviolet light produces a rigid cured material. Many of their test prints are bio-analogs, unsurprisingly.

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Ask Hackaday: Are You Wearing 3D Printed Shoes?

July 10, 2025 by 50 Comments

We love 3D printing. We’ll print brackets, brackets for brackets, and brackets to hold other brackets in place. Perhaps even a guilty-pleasure Benchy. But 3D printed shoes? That’s where we start to have questions.

Every few months, someone announces a new line of 3D-printed footwear. Do you really want your next pair of sneakers to come out of a nozzle? Most of the shoes are either limited editions or fail to become very popular.

First World Problem

You might be thinking, “Really? Is this a problem that 3D printing is uniquely situated to solve?” You might assume that this is just some funny designs on some of the 3D model download sites. But no. Adidas, Nike, and Puma have shoes that are at least partially 3D printed. We have to ask why.

We are pretty happy with our shoes just the way that they are. But we will admit, if you insist on getting a perfect fitting shoe, maybe having a scan of your foot and a custom or semi-custom shoe printed is a good idea. Zellerfield lets you scan your feet with your phone, for example. [Stefan] at CNC Kitchen had a look at those in a recent video. The company is also in many partnerships, so when you hear that Hugo Boss, Mallet London, and Sean Watherspoon have a 3D-printed shoe, it might actually be their design from Zellerfield.

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Mark Setrakian and Adam Savage investigate a massive prop hand

17 Year Old Hellboy II Prop Still Amazes

May 30, 2025 by 7 Comments

The AI effects we know these days were once preceded by CGI, and those were once preceded by true hand-built physical props. If that makes you think of Muppets, this video will change your mind. In a behind-the-scenes look with [Adam Savage], effects designer [Mark Setrakian] reveals the full animatronic glory of Mr. Wink’s mechanical fist from Hellboy II: The Golden Army (2008) – and this beast still flexes.

Most of this arm was actually made in 2003, when 3D printing was very different than what we think of today. Printed on a Stratasys Titan – think: large refrigerator-sized machine, expensive as sin – the parts were then hand-textured with a Dremel for that war-scarred, brutalist feel. This wasn’t just basic animatronics for set dressing. This was a fully actuated prop with servo-driven finger joints, a retractable chain weapon, and bevel-geared mechanisms that scream mechanical craftsmanship.

Each finger is individually designed. The chain reel: powered by a DeWalt drill motor and custom bevel gear assembly. Every department: sculptors, CAD modelers, machinists, contributed to this hybrid of analog and digital magic. Props like this are becoming unicorns.

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3D Filament lizards show decomposable joints

Sustainable 3D Prints With Decomposable Filaments

May 30, 2025 by 24 Comments

What if you could design your 3D print to fall apart on purpose? That’s the curious promise of a new paper from CHI 2025, which brings a serious hacker vibe to the sustainability problem of multi-material 3D printing. Titled Enabling Recycling of Multi-Material 3D Printed Objects through Computational Design and Disassembly by Dissolution, it proposes a technique that lets complex prints disassemble themselves via water-soluble seams. Just a bit of H2O is needed, no drills or pliers.

At its core, this method builds dissolvable interfaces between materials like PLA and TPU using water-soluble PVA. Their algorithm auto-generates jointed seams (think shrink-wrap meets mushroom pegs) that don’t interfere with the part’s function. Once printed, the object behaves like any ordinary 3D creation. But at end-of-life, a water bath breaks it down into clean, separable materials, ready for recycling. That gives 90% material recovery, and over 50% reduction in carbon emissions.

This is the research – call it a very, very well documented hack – we need more of. It’s climate-conscious and machine-savvy. If you’re into computational fabrication or environmental tinkering, it’s worth your time. Hats off to [Wen, Bae, and Rivera] for turning what might otherwise be considered a failure into a feature.

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You Can 3D Print These Assistive Typing Tools

May 22, 2025 by 8 Comments

Typing can be difficult to learn at the best of times. Until you get the muscle memory down, it can be quite challenging. However, if you’ve had one or more fingers amputated, it can be even more difficult. Just reaching the keys properly can be a challenge. To help in this regard, [Roei Weiman] built some assistive typing tools for those looking for a little aid at the keyboard.

The devices were built for [Yoni], who works in tech and has two amputated fingers. [Roei] worked on many revisions to create a viable brace and extension device that would help [Yoni] type with greater accuracy and speed.

While [Roei] designed the parts for SLS 3D printing, it’s not mandatory—these can easily be produced on an FDM printer, too. For SLS users, nylon is recommended, while FDM printers will probably find best results with PETG. It may also be desirable to perform a silicone casting to add a grippier surface to some of the parts, a process we’ve explored previously.

The great thing about 3D printing is that it enables just about anyone to have a go at producing their own simple assistive aids like these. Files are on Instructables for the curious. Video after the break.

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