Overview

This project documents my full process of modifying a Logitech G Pro X Superlight using a custom 3D printed shell.

Recently, I purchased a 3D printer to support my day-to-day work and personal projects. I’ve always been deeply interested in computer peripherals, particularly mice focused on performance, weight, and efficiency. Over time, I’ve built a small collection that includes models like the ENDGAME OP1 8k, the Logitech G PRO X Superlight, and the WLMouse Beast X Mini.

Alongside mice, I’ve experimented with different mousepads, ranging from handcrafted cloth pads such as the Artisan Hayate Otsu and the Key-83, to my current daily driver: a WALLHACK VA-005 glass mousepad. This level of attention to detail comes from a long background in competitive gaming. Throughout my childhood and teenage years, I played and competed in titles like CS:GO and Valorant, even earning prize money along the way.

That said, this project isn’t about my gaming history.

The goal of this build was to explore my new 3D printer, understand the limits and capabilities of different materials, and see how 3D printing could be meaningfully integrated into another long-standing hobby. Rather than presenting a perfect outcome, this post focused on the real process — including iterations, adjustments, and lessons learned along the way.

Overview 1 Overview 2

This wasn’t a clean or straightforward process. Some parts worked immediately, others required multiple iterations, reprints, and adjustments.

This post covers:

  • Printing setup
  • Support tuning
  • Assembly
  • Failure analysis
  • Lessons learned

Tools & Materials

Hardware

  • Logitech G Pro X Superlight
  • Bambulab P1S
  • Textured PEI Plate

Filament

  • Creality CR-PETG (Black)

Tools

  • Precision screw driver set
  • Plastic pry tools
  • Tweezers
  • Flush cutters

Software

  • Bambu Studio

Printing Process

All parts were printed on a Bambu Lab P1S using a textured PEI plate and black PETG filament.

The textured PEI plate was used without glue. Both the build plate and the nozzle were cleaned before printing to ensure proper first-layer adhesion. PETG tends to stick aggressively to smooth surfaces, so the textured plate helped avoid damage during part removal.

PETG also introduces challenges with supports. While the material performs well structurally, improper support settings can result in surface scarring or fused interfaces, which became a recurring issue during early attempts.

Printer & Environment Setup

  • Printer: Bambu Lab P1S
  • Build Plate: Textured PEI
  • Filament: Creality CR-PETG (Black)
  • Enclosure: Closed
  • Adhesion: Clean plate (no glue used in this print)

A closed enclosure was necessary to maintain consistent temperatures and reduce warping, especially for thinner shell sections.

Slicer & Profile

A modified PETG profile was used, prioritizing:

  • Controlled cooling
  • Reduced print speed on outer walls
  • Higher reliability over print time The focus was not on achieving the fastest print possible, but on minimizing deformation and layer inconsistencies on thin structural sections.

Support Strategy

Support tuning was one of the most time-consuming parts of this project.

Early prints suffered from:

  • Supports fusing too aggressively to the shell
  • Visible surface damage after removal
  • Broken edges during cleanup Several iterations were required to balance:
  • Support density
  • Interface distance
  • Support angle thresholds Tree supports improved accessibility, but PETG still required careful post-processing to avoid damaging thin walls and mounting points.

The shell was printed in multiple plates:

  • Main shell components
  • Click mechanisms / secondary parts

Each plate was monitored during the early layers to confirm adhesion and avoid PETG-related issues such as stringing or edge lifting. Once stable, the prints completed without extrusion or layer-shift issues.

At this stage, all parts printed successfully, but support density and proximity would later create significant challenges during post-processing, which are covered in the next section.

Printing Issues & Fixes

Several issues appeared during the first printing attempts, mostly related to support behavior and tolerances.

The most common problems were:

  • Supports bonding too aggressively to the shell
  • Surface damage after support removal
  • Minor deformation on thin structural sections

Because PETG tends to fuse more easily than PLA, early support settings were too dense and left visible scarring on the interior surfaces. Reducing support density and increasing interface distance helped, but required multiple test prints to find a usable balance.

Another recurring issue was dimensional accuracy. Small deviation in wall thickness or internal clearances caused fitment problems during assembly. Some areas required light sanding and cleanup, but others clearly needed design adjustments rather than post-processing fixes.

These issues reinforced the importance of treating functional prints differently from purely cosmetic ones.

Assembly Process

Assembly began by carefully transferring all internal components from the original mouse into the printed shell.

The following components were installed:

  • Main PCB
  • Sensor module
  • Scroll wheel and encoder
  • Ribbon cables
  • Switches
  • Mounting screws

Due to the tighter tolerances of the custom shell, special attention was required during cable routing and component alignment. The internal layout was designed to closely match the original geometry, which helped reduce friction during installation.

After final assembly, the shell closed properly without forcing any components into place. All mounting points aligned correctly, and no structural stress was observed.

Once powered on, the mouse booted normally and all inputs functioned as expected.

Final Results

After assembly, the mouse performed as intended. In hand, the shell felt noticeably lighter without sacrificing rigidity, closely matching the feel of commercial ultralight designs.

All primary functions were tested:

  • Sensor tracking
  • Left and right click
  • Scroll wheel
  • Responsiveness

The sensor tracked accurately, click registered consistently, and the scroll wheel behaved normally. Structurally, the shell felt solid despite its reduced weight, confirming PETG as a suitable material for this type of functional mod.

While this version was primarily focused on validating the shell and assembly workflow, the result proved that a fully functional shell is achievable with careful tuning and iteration.

Lessons Learned

This project reinforced several key takeaways:

  • Functional 3D prints require tighter tolerances than cosmetic parts
  • PETG provides durability and flexibility, but demands careful support tuning
  • Small dimensional differences can significantly affect assembly quality
  • Iterative testing is essential when working with real hardware
  • Documenting the full process adds long-term value beyond the final result

Overall, this mod served as a successful proof of concept. The workflow, material choices, and assembly process established a strong foundation for future revisions and refinements.