How do Prague firefighters use a 3D printer between emergency calls?

A hobbyist starts a pilot program

The brigade handles up to 2,500 emergency dispatches every year. Founded in 1853, it is the oldest professional fire service in the country. Crews cover narrow medieval streets and modern skyscrapers, protecting more than a million residents and millions of yearly tourists.

Lukáš, an active firefighter and home 3D printing hobbyist, brought the idea to the station. Small components constantly need quick adjustments. A flashlight bracket snaps. A radio mount loosens. The crew visited the Prusa Research factory. Seeing the potential, Prusa provided a printer for a pilot program. The firefighters immediately ran with it.

Printing on shift

Around 67 firefighters work at the central station across three 24-hour shifts. One trained operator per shift handles the printer and keeps material waste to a minimum.

They print almost everything in signature Prusa Orange. The color matches the high-vis orange on Czech fire engines. It makes tools easy to spot inside dark truck compartments when seconds count.

Every printed part gets tested hard before it hits the field. Exposure to extreme heat and direct flame happens inside their Flashover Container training facility. They have already replaced slippery wooden door wedges with 3D printed versions that actually grip wet tiles. They swapped clunky metal elevator keys for lightweight prints crew members can keep right in their jacket pockets.

Cost savings and mental health

Replacing components like broken helmet brackets used to require purchasing expensive original vendor parts. Now it happens in-house on demand. The crew reports cost savings of around 90 to 95 percent.

For water rescues, they print hard-to-find dry suit pressure plugs to run leak tests locally instead of waiting weeks for rare supplier parts.

Station leadership noticed an unexpected benefit. Firefighting is a tough job. Between intense calls, keeping your mind active is just as important as staying physically fit. Printing gives a creative outlet. It keeps the crew sharp while they build custom gear that makes their jobs easier.

Cybersecurity rules shape the choice

As a state agency, the Czech Fire Rescue Service must follow tight cybersecurity rules set by NÚKIB. Most consumer 3D printers force users onto external clouds, run closed software, and route data through remote servers. That opens the door to leaked designs or remote tampering.

Prusa fits the strict public-sector rules. Hardware runs completely air-gapped. Files transfer using a physical USB drive or a secure local network via PrusaLink, with zero contact with outside cloud servers. Every printer is made in the Czech Republic. There are no hidden “black box” components or third-party backdoors to worry about.

Specialized divisions go further

Two specialized divisions take additive manufacturing beyond daily station needs.

The Technical Department keeps heavy rescue trucks, ladder rigs, and water pumps running. Instead of waiting months for factory parts, they print hard-to-find interior trim, custom hose adapters, and heavy-duty tool mounts in-house.

The USAR Unit is Prague’s elite search-and-rescue team deployed globally to earthquakes and building collapses. When carrying gear through rubble, every ounce counts. They print lightweight camera mounts, sensor cases, and rugged transport gear designed to take a beating. Both divisions represent advanced additive manufacturing hubs that will be featured in upcoming deep-dive case studies.

A nationwide network shares designs

Other fire stations across the Czech Republic have also adopted 3D printing. Rather than re-inventing the wheel, regional brigades actively exchange digital models, test results, and printing tips. They share open-source designs on Printables.com and collaborate during regional workshops.

“That’s how it always starts,” the firefighters smile. “First you print a Christmas gift, then a door wedge, then a helmet mount… and before you know it, you can’t imagine running the station without a 3D printer.”