In general, if a laptop suffers any physical damage, its owner will most likely be able to obtain a suitable replacement part, either new or taken from another similar unit. However, there are cases where 3D printing is definitely worth considering as a solution. The YouTuber Polymatt only wanted to replace the frame of an IBM ThinkPad 701C... but after thinking it over, he ended up printing the entire laptop...
My "phase" with multiple computers at home is behind me, but I still keep an old Gateway LT25 netbook in relatively acceptable condition. This was possible thanks to a nearly complete replacement of its casing, coming from an identical unit with multiple motherboard failures. Being a model with more than ten years under its belt, I imagine I won't be able to repeat that trick, and if something breaks it will stay that way, unless...
... 3D printing comes to the rescue. The idea isn't new: many enthusiasts are printing brackets, buttons, switches, keys, covers, latches, hooks, and every conceivable part. However, Polymatt on YouTube (whom we remember well for his extreme restoration of IBM laptops), decided to go a step further and create a total replacement for the casing of a ThinkPad 701C.
How to print a laptop
Polymatt recommends creating a "digital twin" as quickly as possible, and working on it to correct errors and adjust tolerances. Taking measurements is barely a tiny piece of a gigantic puzzle, because we're not only operating in tenths of a millimeter, but there are two essential aspects to consider: robustness, and the type of material.
In other words, the laptop doesn't stay still, and this is especially true with the 701C and its "butterfly keyboard." Creating the front frame for the screen is one thing: combining all the parts, incorporating aluminum brackets, installing the hinges, operating the keyboard mechanism without problems, and not destroying anything in the process, is in a completely different league. Add to that the natural changes of the material. Plastic shrinks as it cools, and if a piece seems to work at first, it might end up "out of tolerance" within a couple of hours. Even the orientation of the print has the potential to affect the pieces.
Polymatt also took the trouble to incorporate other details like the icons, the exact model, and of course, the IBM ThinkPad logo. The final result is excellent... but not perfect. Polymatt recommends following this path if it's a "showpiece," something to show and capture the curiosity of visitors. On the other hand, if the plan is daily use, it would be better to seek other manufacturing methods. Even printing PETG filament reinforced with carbon fiber, there is too much "flex" in the plastic, and that always causes problems in the long run...
