Reviving Old 3D Printers - Workshop at HKA
- EU4M
- Oct 31, 2024
- 3 min read
In September, a group of 3rd semester Students of the EU4M Program participated in a workshop to revive two long-abandoned and forgotten 3D printers. The idea was simple but ambitious: take machines that had been gathering dust and make them functional again using open-source boards.
What started as a two-week workshop grew into over four weeks of intense learning, troubleshooting, and collaboration. Every challenge faced along the way brought new lessons, showing that sometimes the best way to learn is to dive into the unknown. This is the story of how the students brought two printers back to life, one step—and one axis—at a time.
Kicking Things Off: From Components to Connections
On the first day, we set the stage by introducing the two printers: a modified 5-axis Prusa and a conventional Cartesian printer. The students explored the basics of open-source Duet boards, which would serve as the heart of these machines.
The next day, the students got their hands dirty, familiarizing themselves with the core components of a 3D printer. They learned to identify thermistors, stepper motors, endstops, resistors, sensors, and other essential parts. Then came the exciting part—wiring and krimping the components to the boards and testing basic functions using G-code. The room buzzed with problem-solving energy, and each connection brought a sense of accomplishment.
The Midweek Breakthrough: Assembly, Configuration, and Inspiration
By Wednesday, the students started assembling the two printers, carefully placing components, and working through the quirks of machines that hadn’t been touched in a long time. This was also the day we welcomed Luca Breseghello, a former colleague now at DTU Engineering Technology, whose talk on digital fabrication in the construction industry inspired the students. Luca shared examples of his work on 3D printing applications for concrete structures and explained how combining computational design tools and manufacturing processes can unlock new, more sustainable solutions across all industries. His insights gave the students new perspectives just as they were deep in bringing the old machines back to life.
Challenges and Triumphs: Breathing Life into Old Printers
As the weeks progressed, the 5-axis printer proved to be the more manageable of the two. Although we couldn’t unlock the full 5-axis functionality within the limited time, the students successfully got it running with 3 functional axes—an achievement they celebrated with their first test prints.
The Cartesian printer, however, presented more of a puzzle. Issues with the hot end and print bed caused delays, and solutions had to be improvised. The students borrowed parts—like nozzles and thermistors—from another printer, thanks to the generosity of Meron. Despite the frustrations, the students stayed motivated and determined to make the printer work.
Extending the Workshop: Going Beyond Two Weeks
Though the original plan was to complete everything in two weeks, the students requested extra time. Over the next few weeks, they kept meeting to tweak, test, and fine-tune the machines. Each session brought them closer to success, but it also taught them the value of persistence.
In the end, both printers were revived—their outdated electronics were replaced with open-source solutions—ready for new projects. Each student contributed by improving what already existed rather than throwing it away.
The Final Task: Printing and Reflection
As the final step, each student was asked to submit a video explaining their work: how they connected the printers, configured the components in the config.g file, and used the Duet board to run the printers. Their task also included printing a Benchy, the classic 3D printing benchmark, as proof that the printers were fully operational.
One of the students, Natalia Algarin, generously allowed us to share her project here. You can explore her work in the video above.
Conclusion: Circular Engineering in Practice
This workshop was more than just about fixing machines; it was about adopting a mindset of circular engineering—upgrading instead of replacing and improving instead of discarding. The students learned that even outdated machines still have potential by reactivating these old printers. We believe this type of sustainable thinking should be a core part of engineering education.
A heartfelt thank you to Luca Breseghello for sharing his expertise, EU4M for making this workshop possible, and everyone who contributed to this experience. With the EU4M scholarship applications open until January, we hope to see even more students join us for exciting projects like this one in the future.
Stay tuned for more updates from the EU4M Alumni Club!
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