{"id":2977,"date":"2025-08-25T19:48:42","date_gmt":"2025-08-25T23:48:42","guid":{"rendered":"https:\/\/sites.williams.edu\/makerspace\/?p=2977"},"modified":"2026-04-13T12:54:34","modified_gmt":"2026-04-13T16:54:34","slug":"faster-prints-fewer-headaches-upgrading-our-fleet-to-prusa-mk4s","status":"publish","type":"post","link":"https:\/\/sites.williams.edu\/makerspace\/projects\/faster-prints-fewer-headaches-upgrading-our-fleet-to-prusa-mk4s\/","title":{"rendered":"Environmentally Sustainable 3D Printer Upgrades Reduces E-Waste"},"content":{"rendered":"
\"Alice<\/a>

Alice Sore ’27 upgraded our 3D printers in an environmentally sustainable manner by replacing specific componentry on our older models. This was both cost-efficient and eliminated disposing them as electronic waste (e-waste). CNBC projects that global e-waste is projected to reach 82 million metric tons by 2030.<\/p><\/div>\n

Out of everything we use here at the Makerspace, our 3D printer fleet is the MVP. Students and faculty rely on these machines constantly, cranking out everything from quick concept models to full-blown research prototypes. So when we had the chance to upgrade our entire fleet to the Prusa MK4S, we jumped on it. First, we sustainably upgraded our two older MK3S printers by swapping out componentry, resulting in like-new printers without causing the typical e-waste so ubiquitous to technology. Unfortunately, our aged Dremel 3D45 printers were built as single-use machines, (without options for forward compatibility) and so we had to dispose of those (after removing potentially useful parts) as e-waste. We use Prusa 3D printers because they are reliable AND because the Prusa ecosystem (company and community) encourages environmentally sustainable upgrades and modifications.<\/span><\/p>\n

Spoiler:<\/strong> totally worth the effort.<\/span><\/p>\n

Environmentally Sustainable 3D Printer Upgrades Reduces E-Waste<\/h2>\n
\"Alice's<\/a>

Alice’s 3D printer upgrades mean much faster print speeds and they make nozzle swaps incredibly simple.<\/p><\/div>\n

Let’s be real. The MK4S upgrade isn’t just a tune-up. We basically gave our printers a heart transplant. Actually, several transplants. Almost every single part got swapped out except the frame and power supply. When you use these printers now, you’re running on next-gen hardware.<\/span><\/p>\n

So what changed? Let’s break it down.<\/span><\/p>\n

The Nextruder is a game changer.<\/b> Think of it like switching from a clunky flip phone to a smartphone: faster, smoother, and way easier to customize. This new extruder (which we already love on our Prusa XL) cranks up print speeds and makes nozzle swaps incredibly simple. Like swapping AirPods simply.<\/span><\/p>\n

No more manual bed leveling.<\/b> The load cell handles it automatically, using the printer’s nozzle to probe the bed. Set it and forget it.<\/span><\/p>\n

Hello, 32-bit mainboard.<\/b> This brain upgrade unlocks fancy software features like Input Shaping and Pressure Advance, which translate to higher quality prints with cleaner layers and fewer weird artifacts. Plus, native support for Prusa Connect means Wi-Fi everything. Less standing around waiting, more grabbing coffee while your print starts itself.<\/span><\/p>\n

Installing the Upgrades<\/b><\/h2>\n

Each upgrade took about eight hours. That’s a whole day of taking the printer apart screw by screw, then putting it back together like a giant LEGO set with instructions that actually make sense. Prusa nailed the documentation. Every step was clear, every part was labeled (even the screws!), and honestly? It was kind of satisfying when each printer roared back to life on the first test print.<\/span><\/p>\n

Lights, Camera, Printing!<\/b><\/h2>\n

We also had to get creative with our camera setup. The old method of connecting a Raspberry Pi Zero directly to the MK3S doesn’t work with the MK4S hardware. No problem. We kept the same gear and just reimagined how to use it.<\/span><\/p>\n

Here’s the setup now: each MK4S has a custom 3D printed arm with a ball joint socket. We mount a case containing a Raspberry Pi Zero W and a Raspberry Pi Camera Module 3 NoIR right there. Each Pi runs Raspberry Pi OS Lite, connects to our network over Wi-Fi, and fires off a new still image to Prusa’s servers every 10 seconds. You can check in on your print anytime without walking over.<\/span><\/p>\n

Down the road, we’re planning to upgrade the code when Prusa Connect adds support for live video feeds. Because who doesn’t want to watch their print in real time?<\/span><\/p>\n

What This Means for You<\/b><\/h2>\n

So what does all this nerdy tinkering actually mean for you?<\/span><\/p>\n