How Firefighters Use 3D Printing to Save Lives, Time and Money

They handle up to 2,500 emergency dispatches every year. They save lives, help people in need, and serve. And for being able to do that, they need reliable, precise, rugged, and custom equipment. That’s why firefighters from the Fire Rescue Service of the Capital City of Prague implemented 3D printing to prepare for routine missions.

Founded in 1853, The Fire Rescue Service of Prague is the oldest professional fire brigade in the country. Today, its crews cover everything from narrow medieval streets to modern skyscrapers, keeping more than a million locals and millions of yearly tourists safe.

At the busy central station, organization is critical. Right next to their trucks and heavy cutters, the crew uses a 3D printer (Prusa CORE One L) to make custom mounts, shield delicate gear, and keep specialized equipment locked down and ready for action.

How 3D Printing Transforms Front-Line Efficiency

This project didn’t come from top management. It started with Lukáš, an active firefighter who happens to be a 3D printing hobbyist at home.

At a fire station, small components constantly need quick adjustments or custom fixes. A flashlight bracket snaps, a radio mount loosens up, or a tool needs securing inside a half-million-dollar fire engine.

Having 3D printing right at the station significantly streamlines the entire process of getting spare parts and custom equipment. Rather than navigating complex administrative steps, the team can immediately produce exactly what they need on-site. It’s a practical, high-value solution that gives the crew total flexibility and speeds up everyday fixes.

As Lukáš describes it: “Having a 3D printer right here in the station changes everything,” the crew explained. “We design it, print it, and fix the issue on the spot, exactly how we want it.”

What started as side-project tinkering took off after the crew visited the Prusa Research factory. Seeing the potential, Prusa provided a printer for a pilot program at the station, and the firefighters immediately ran with it.

Keeping the Mind Sharp Between Calls

Around 67 firefighters work at the central station across three 24-hour shifts, with one trained operator per shift to handle the printer and keep material waste to a minimum. Beyond saving money on gear, station leadership noticed an unexpected benefit: it’s great for the crew’s mental health.

“Firefighting is a tough job,” the crew explains. “Between intense calls, keeping your mind active is just as important as staying physically fit. Printing gives us a creative outlet. It keeps us sharp while we build custom gear that makes our jobs easier.”

To handle everything from tiny clips to massive truck organizers, the team relies on the Prusa CORE One L. Its enclosed, temperature-controlled setup lets them use tough, high-performance materials without worrying about parts warping. They print almost everything in signature Prusa Orange, because it matches the high-vis orange on Czech fire engines and makes tools easy to spot inside dark truck compartments when seconds count.

Putting It to the Test (and Saving Big)

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

Financially, the positive impact was immediate. Replacing components like broken helmet brackets, which used to require purchasing expensive original vendor parts, can now be done in-house on demand, delivering cost savings of around 90 to 95 percent. For water rescues, they print hard-to-find dry suit pressure plugs in-house to run leak tests locally instead of waiting weeks for rare supplier parts.

The efficiency gains extend to the station walls, too. Rather than relying on commercial tool rails, the crew prints fitted bracket sets tailored to their needs at a fraction of the cost. Custom-shaped to hold axes, mops, and squeegees, these mounts keep everything locked down when the trucks roll out on high-speed dispatches.

Cybersecurity in Critical Infrastructure

As a state agency, the Czech Fire Rescue Service has to follow tight cybersecurity rules set by NÚKIB (the National Cyber and Information Security Agency). That makes most consumer 3D printers a dealbreaker. They force you onto external clouds, run closed software, and route data through remote servers, opening the door to leaked designs or remote tampering.

Prusa fits right into these strict public-sector rules:

• Runs 100% offline: Hardware runs completely air-gapped. You transfer files using a physical USB drive or a secure local network (via PrusaLink), with zero contact with outside cloud servers.
• Built locally in Prague: Because every printer is made in the Czech Republic, there are no hidden “black box” components or third-party backdoors to worry about.

Technical Department and Search-and-Rescue Teams Taking it Further

While station firefighters focus on tactical gear and day-to-day ergonomics, two specialized divisions within the brigade take additive manufacturing even further:

1. The Technical Department

These crews keep 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.

2. The USAR Unit

Prague’s elite search-and-rescue unit gets deployed globally to earthquakes and building collapses. When you’re carrying gear through rubble, every ounce counts. They print lightweight camera mounts, sensor cases, and rugged transport gear designed to take a beating.

Both the Technical Department and USAR represent advanced additive manufacturing hubs that will be featured in upcoming deep-dive case studies.

A Nationwide Network of Innovation

Other fire stations across the Czech Republic have also adopted 3D printing.

Rather than re-inventing the wheel, these regional brigades actively exchange digital models, test results, and printing tips. By sharing open-source designs on Printables.com and collaborating during regional workshops, Czech firefighters are building a decentralized, crowd-sourced network of emergency solutions.

As the crew puts it: “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.”