Ultimate Guide to 3D Printing for Overlanders: 3D Print Survival Gear, Camp Gear, Emergency Repairs & More

Here’s what you’ll be uncovering in this post:

• How 3D printing empowers overlanders to create custom gear, survival tools, and emergency repairs on the go
• The best types of portable 3D printers, essential filaments, and power setups for off-grid printing
• Tips and future trends to maximize self-reliance and innovation on your adventures

When Formula 1 drivers like Lewis Hamilton break a wing or lose a part during practice, their pit crew can fabricate a replacement in minutes. If you’ve watched Formula 1: Drive to Survive, you’ve seen how crucial these rapid fixes are to keep cars on track. Now, overlanders are bringing that same on-demand manufacturing power to the backcountry with portable 3D printers.

Broken camp gear, snapped vehicle parts, or lost essential items are all common problems when you're miles from the nearest store. But what if you could manufacture a solution on the spot instead of cutting your trip short?

That's exactly what smart overlanders are doing. Compact 3D printers are turning adventure rigs into mobile workshops, creating custom parts and emergency fixes wherever the trail takes you. 

From 3D printing camping gear like custom spice racks and utensil holders to 3d print survival gear such as emergency whistles and repair tools, the possibilities are endless.

Why 3D Print While Overlanding? More Reasons Than You'd Think

When people first hear about bringing 3D printers on camping trips, many roll their eyes. It's like taking a laptop to a yoga retreat; you’re completely missing the point. You might question them at first, but their power becomes undeniable once put to work. 

Emergency Repairs & Quick Fixes

Murphy's Law loves overlanders. When something is bound to break, it often chooses the worst moment to do so. That plastic bracket holding your solar panel? Gone. The handle on your water jug? Snapped. The mounting clip for your GPS? Vanished into the void.

Instead of limping home or jerry-rigging a solution with duct tape and zip ties (though let's be honest, that'll still happen sometimes), you can actually print a replacement part. 

Overlanders can print replacement parts like mounting brackets in under an hour when their originals break on the trail, often ending up with versions that are even stronger than the originals.

Custom Gear & Modifications

Here’s when 3D printing camping gear takes things to a whole new level. Every overlanding rig is different, and sometimes you need a solution that simply doesn't exist in stores. 

Maybe you need a custom mount for your specific tablet in your exact truck model, or a storage organizer that fits the weird dimensions of your gear box.

3D printing camping gear lets you craft precise designs tailored to your needs. People have printed custom spice rack inserts for camp kitchens, phone mounts that fit dashboards perfectly, and even specialized holders for camp showers that clip onto roof racks. Your options are virtually limitless.

On-Demand Spare Parts & Tools

Carrying every possible overlanding spare part would require a semi-truck. But with a 3D printer, you can carry the digital files instead and print parts as needed. Lost the cap to your water bottle? Print a new one. Need a specific adapter for your camp shower? Design it and print it.

Many overlanders keep a USB drive loaded with files for common replacement parts, everything from tent stakes to bottle caps to simple tools. It's like having a hardware store in a thumb drive.

Increased Self-Reliance and Crisis Readiness

There’s a special pride that comes from handling challenges with your own abilities and creativity. 3D printing camping gear takes that overlanding self-reliance to the next level. When you can literally manufacture solutions to problems in the field, you're not just camping, you're pioneering.

Knowing you can handle unexpected repairs or create needed gear gives you the confidence to venture further from civilization and stay out longer.

Cost-Effective Repairs and Sustainable Overlanding Solutions

A simple plastic clip might cost $15 at an auto parts store, but you can print it for about 30 cents in materials. Over time, those savings add up, especially if you're printing multiple items or custom solutions.

And from an environmental standpoint, being able to repair instead of replace is huge. Why throw away a perfectly good camp chair just because one plastic part broke? Print the replacement and keep using it for years.

Choosing the Right Portable 3D Printer for Overlanding

Not all 3D printers are created equal, and using one for overlanding adds some unique requirements. You want something rugged enough to cope with bumpy trails, gritty dust, and unpredictable weather.

Key Considerations for Overlanding Printers

• Durability & Ruggedness: Your portable 3D printer for overlanding needs to survive bouncing down washboard roads and camping in dusty conditions. Look for ruggedized 3D printers with solid construction and enclosed designs that protect the moving parts from debris.
• Size & Weight: Space is precious in any overlanding setup. You want something compact enough to store securely but large enough to print useful parts. Most overlanders find that printers with moderately sized build volumes strike the perfect balance.
• Power Consumption: This is crucial for off-grid adventures. Look for printers that run efficiently on 12V or can work well with small inverters. Some newer models are surprisingly power-efficient.
• Filament Compatibility: Your printer needs to handle tough materials like PETG and ABS, not just basic PLA. We’ll dive deeper into this in the following section.
• Ease of Use & Maintenance: When you're camping, you don't want to spend hours calibrating your printer. Look for models with auto-bed leveling and other user-friendly features.

Types of Printers & Their Suitability

• FDM (Fused Deposition Modeling) Printers: These are your best bet for overlanding. They're relatively affordable, can print strong parts with durable materials, and are much more forgiving of environmental conditions than other types.
• SLA/Resin Printers: While they produce incredibly detailed prints, resin printers are generally not suitable for overlanding. They're messy, require UV light for curing, use toxic materials, and produce parts that can be brittle. Save these for your home workshop.

Recommended Features

Look for printers with auto-bed leveling (you’ll find this feature to be a true lifesaver when you need it most), direct drive extruders for flexible materials, and good community support. You want a printer where you can easily find replacement parts and troubleshooting help online.

Essential Filaments for Off-Grid 3D Printing Camping Gear

Picking the right filament is equally crucial as selecting your printer. Each project has its own requirements, and certain materials perform far better outdoors than others.

PLA (Polylactic Acid)

• The Good: PLA is beginner-friendly, prints easily, and is biodegradable. It's great for testing designs and making prototypes.
• The Not-So-Good: PLA gets soft at relatively low temperatures (around 140°F), which means it can warp in direct sunlight or a hot car. It's also somewhat brittle, so it's not ideal for parts that need to flex or take impact.
• Best For: Interior organizers, temporary fixes, and testing new designs.

PETG (Polyethylene Terephthalate Glycol)

This is often the go-to filament for most overlanding prints. PETG strikes a great balance between printability and performance.

• The Good: Strong, impact-resistant, good heat resistance (up to about 180°F), decent UV resistance, and still relatively easy to print.
• The Not-So-Good: Can be a bit stringy during printing, and requires slightly higher temperatures than PLA.
• Best For: General-purpose parts like brackets, containers, tool holders, and most camp gear.

ABS/ASA (Acrylonitrile Butadiene Styrene / Acrylonitrile Styrene Acrylate)

• The Good: Very strong, excellent heat resistance, and ASA has outstanding UV resistance. These are the materials for serious outdoor parts.
• The Not-So-Good: Requires an enclosed printer due to fumes and warping tendencies. ASA is harder to find than ABS.
• Best For: High-stress parts, anything exposed to direct sunlight, exterior overland vehicle components.

TPU (Thermoplastic Polyurethane)

• The Good: Flexible like rubber, impact-resistant, perfect for gaskets and seals.
• The Not-So-Good: Challenging to print, especially on printers without direct drive extruders. Prints slowly.
• Best For: Gaskets, vibration dampeners, flexible caps, protective boots for equipment.

Filament Storage & Handling

Filament is basically plastic spaghetti that really, really hates moisture. In humid conditions or rain, filament can absorb water and print poorly. Keep your 3D printer filament in sealed containers with silica gel packets, and protect it from direct sunlight.

Powering Your Mobile 3D Printing Camping Gear Workshop

Things get technically challenging here. 3D printers draw a lot of power, and you’re setting them up in regions where electrical outlets are nowhere in sight.

Solar Power Solutions

Solar is often the best option for extended trips. A typical portable 3D printer might use 100-200 watts while printing, so you'll want a solar setup that can handle that load, and also charge your batteries.

A 400-600 watt solar array with a good charge controller and battery bank can easily handle solar-powered 3D printing during the day while keeping your batteries topped up. LiFePO4 batteries are particularly good for this application because they can handle the cycling and power demands.

Vehicle Power & Inverters

Your vehicle's alternator can charge batteries while driving, giving you power for printing at camp. If you're printing while the engine is running, you can even use the alternator directly with a good DC-DC charger.

For inverters, get a pure sine wave model. Modified sine wave inverters can cause issues with some 3D printer control boards.

Battery Systems & Management

A good battery monitor is essential so you don't accidentally drain your batteries and leave yourself stranded. Plan your printing for times when you have plenty of power available, and always keep a reserve for essential systems.

Designing & Finding 3D Models for Overlanding

Half the battle with 3D printing camping gear is getting the right files to print. Fortunately, an extensive community of creators shares their designs online.

Online 3D Model Repositories

• Thingiverse is probably the largest free repository of 3D models. Search for terms like "overlanding," "off-road," "camping," and your specific vehicle brand. You'll find everything from simple clips to complete camp kitchen systems.
• Printables (by Prusa) is newer but growing fast, with high-quality models and good search features.
• MyMiniFactory and Cults3D also have great collections, though some models require payment.

Follow makers who design overlanding-specific gear. Once you find someone whose designs work well for you, check out their other models.

Basic CAD Software for Custom Designs

There’s no need to feel overwhelmed about designing parts yourself. Tinkercad is an online CAD program that’s beginner-friendly and simple to use. You can learn the basics in an afternoon and start creating simple custom parts immediately.

For more advanced work, Fusion 360 offers a free personal license and has tons of YouTube tutorials, including CAD software for beginners, custom 3D designs, and so on. It's what many professional designers use, but it's accessible to hobbyists too.

3D Scanning for Replication

If you have a broken part and need to replicate it, smartphone apps like 3D Scanner App or Qlone can create decent 3D scans for simple objects. The quality isn't perfect, but it's often good enough for basic repairs.

Common Overlanding 3D Prints: Real-World Examples

Here are some of the most useful 3D prints that overlanders are actually using on the trail. These aren't just cool concepts. These are proven designs that have saved countless trips and solved real problems in the field.

Vehicle-Specific Parts

• Interior Organizers: Custom center console dividers, glove box inserts, and door panel organizers that fit your exact vehicle.
• Exterior Accessories: Light bar mounting brackets, antenna bases, vehicle recovery gear holders that bolt to specific mounting points.
• Replacement Parts: Dashboard clips, vent covers, and trim pieces that break and cost a fortune to replace from the dealer.

3D Print Camp Gear

• Camp Kitchen Accessories: Spice rack inserts, utensil holders, collapsible cups, and pour spouts for water containers.
• Utility Items: Custom hose adapters, storage box dividers, and mounting brackets for camp furniture.

Overlanders can print custom spice racks designed to fit perfectly in their camp kitchen drawers, with compartments tailored to their exact containers, creating solutions that simply aren’t available in stores.

3D Print Survival Gear

• Emergency Tools: Whistles, fire starter holders, small multi-tools, and emergency repair patches using flexible filament.
• Backup Gear: Spare tent stakes, guy-line tensioners, and replacement parts for critical gear.

Organizational & Convenience Items

• Electronics Management: Cable clips, battery holders, solar panel adjustable stands, and mounts for phones and GPS units.
• Camp Conveniences: Lantern hooks, carabiner organizers, and custom brackets for camp chairs.

The key is thinking about the small plastic parts that make your life easier, but would be impossible to find replacements for in the field.

Tips for Successful 3D Printing in the Wild

Creating prints in the backcountry comes with challenges you won’t face in a regulated workshop environment. Here are some hard-learned lessons from experienced overlanders.

Environmental Factors & Their Impact

• Vibration: Secure your printer well during travel. Even small vibrations can mess up prints. Some people build custom shock-absorbing mounts for their printers.
• Dust & Dirt: Keep your printer covered when not in use. Dust on the build platform can ruin bed adhesion, and dirt in the mechanics can cause jams.
• Temperature Fluctuations: Try to print in stable conditions. Big temperature swings during a print can cause warping and layer adhesion issues.

Pre-Trip Preparation

Test everything at home first. Print with the filaments you plan to take, make sure your files are organized and accessible, and pack essential maintenance tools.

Keep a "repair kit" for your printer: spare nozzles, Allen wrenches, a small tube of bed adhesive, and maybe some spare belts if your printer uses them.

Troubleshooting Common Issues

• Warping: Use a heated bed if your printer has one, or try printing on a raft for better adhesion.
• Layer Issues: Usually caused by temperature fluctuations or mechanical problems. Check your belts and clean your nozzle.
• Clogs: Keep spare nozzles and know how to change them. A clogged nozzle in the field can end your printing session.

Safety Considerations

Proper ventilation is crucial, especially with ABS or ASA filaments. Never print these materials inside your vehicle or tent.

Be careful around hot components; 3D printer nozzles can reach 500°F. As with all electrical devices, ensure that all your connections are tight and your inverter is safely grounded.

The Future of Overlanding & 3D Printing

We’re only beginning to tap into their full potential. Each year, printers become more compact, efficient, and powerful. New filaments are being developed that are stronger, more weather-resistant, and easier to print.

The prediction is that within a few years, having a 3D printer in your overlanding kit will be as common as having a recovery strap. The technology is reaching a tipping point where the benefits clearly outweigh the hassles.

The overlanding community has always been about self-reliance and innovation, and 3D printing fits perfectly into that mindset. As natural problem-solvers, we now have the power to create backcountry solutions instantly with this tool. Imagine being able to 3D print survival gear right at your campsite when you need it most.

Wrapping It Up

3D printing for overlanding isn't just about the cool factor (though it definitely has that). It's about transforming how you approach challenges on the trail. Rather than letting a damaged part ruin your plans, you view it as a moment to design something even stronger.

Being able to design, build, and fix things right where you are unlocks opportunities that seemed impossible not long ago. It broadens what you can do, boosts your confidence, and honestly makes you feel like a magician as you whip out your laptop, create a fix on the spot, and see it come to life through your printer. 

Consider the edge you’d have if you could 3D print survival gear wherever you are, no matter how remote.

Whether you're printing your first custom phone mount or designing complex repair parts for your vehicle, remember that every expert was once a beginner. Begin with the basics, grow your skills over time, and explore without hesitation.

Now get out there and start creating. The trail is waiting, and with a 3D printer in your kit, you're ready for whatever it throws at you.