Make a Spongeless Refillable HP Cartridge 61 62 63 64 65 66 67 68 Integrated Cartridges

HP integrated cartridges have a printhead on the bottom and an electronic ribbon on the side. HP makes two kinds of desktop-integrated cartridges. One is shaped like a square, and the other is more rectangular. 21, 56, 61, 62, and 63 are examples of usually square cartridges. In starter or regular cartridges, there’s an interior wall that holds a tiny sponge. This sponge limits how much ink can be added. The XL cartridge doesn’t have this wall and has a larger sponge. However, the sponge takes up about half of the available space inside the cartridge.

Once the cartridge has been depleted, HP allows the printer to keep printing, but it will not show the ink level. BCH Technologies has found a way to modify an OEM cartridge by installing a refillable cap with a pressure regulator. It is called a spongeless refillable cartridge. This article will demonstrate how to remove the wall, the sponge, and then glue on a unique cover with a pressure regulator, thus making an HP refillable cartridge. These cartridges can allow more space for ink, which, in turn, increases the longevity of your ink cartridges. It will save you valuable time and money in the long run to modify the cartridge this way, so stick with us.

How Do Standard HP Cartridges Work?

HP printers typically utilize black and tricolor ink cartridges. The black cartridge contains black ink only, while the tricolor cartridge contains three chambers that hold cyan, magenta, and yellow ink. You can choose to print in black and white, which pulls ink from the black cartridge, or you can select the color option, which also uses ink from the three-chambered cartridge.

Most standard printers use water, dyes, and pigments to create different ink colors. While some printers keep colors separate, most combine them in a single cartridge, which can be frustrating for some users, because it becomes necessary to replace the whole cartridge once one color runs out.

It’s crucial to note that although HP cartridges may look similar, they are not necessarily compatible with all printers. This is because each cartridge (for instance, HP 60, HP 61, HP 65, HP 67, and so on) is fitted with a specialized chip coded for a specific series of printers. That's why it’s essential to pay attention to which series your printer uses, because each is slightly different.

For instance, HP 62 Standard Yield ink can produce up to 200 pages with the black cartridge and 165 with the tricolor cartridge. On the other hand, HP 64XL High Yield will give you 600 pages on the black cartridge, and 415 in color. That's why, depending on your desired yield size, you should select your printer series accordingly. Here are some additional facts about standard HP ink cartridges you should be aware of:

  • They can last up to 2 years when sealed.
  • Even once your printer starts displaying the “low ink” warning message, you may still be able to get some additional use out of your cartridge by cleaning the printhead nozzle.
  • Most HP printers come installed with enough ink for a few sample prints.
  • Ink cartridges can dry after some time, regardless of whether they’ve been used up or not. That's why it’s essential to use them within a reasonable timeframe.

While HP ink cartridges are an excellent option for those who print on a minimal basis, the costs associated with constantly replacing this ink can add up quickly. This is where it can be advantageous to use a spongeless refillable cartridge.

Required Materials

  • Sandpaper (100-grit or 150-grit)
  • Heavy-duty utility knife
  • 2 rubber bands
  • Superglue (don’t use foam glue)
  • Long-nose pliers

You can find additional materials at (here). Navigate to the modification kit tab on the site and select “For HP'' from the dropdown menu. Here, you can find mod kits for making spongeless cartridges. HP square means that it’s a square-shaped HP cartridge. 

    • SKU:AS-RFC-HPSQ803-LEFT (Click here to buy)
    • 1 black cartridge cover with air pressure assembly and a black refill plug
    • 1 color cartridge cover with an air pressure regulator and color refill plugs
    • 1 flat-headed priming syringe with a silicone tip

This kit modifies HP integrated cartridges, allowing them to be made refillable. HP integrated cartridges have printheads built-in. These cartridges include HP 60, 61, 62, 63, 64, 65, 66, 67, and 68. For international buyers outside of the US and Canada, the kit also supports the following models:

    HP 121 (CC640HE), HP 301 (J3M81AE, N9J72AE), HP 302, HP 304, HP 343, HP 338, HP 650, HP 652 (F6V25AE), HP 662, HP 664 (F6V28AL, F6V29A), HP 678, HP 680 ((F6V27AA)), HP 802, HP 803

The kit is compatible with all cartridges containing a ribbon and printhead. However, different regions may use other names for the same cartridge. For example, South Asia may call one cartridge PG-840, CL-841, while in Europe it’s referred to as PG-540, CL-541. That is why it’s critical to ensure that you are purchasing the correct kit for your printer.

In addition, we recommend this process be completed by those who have experience with printers and refilling ink, as it involves several complex steps that can be difficult for novice learners. To learn more about the modification kit and how to make spongeless refillable HP cartridges, visit

Instruction Video:

Step 1

Note that you should protect two parts of the cartridge in particular during this process. One is the printhead on the bottom of the cartridge, which needs to be guarded against dirt and debris. The other is the electronic ribbon, which you’ll want to protect from the overflow of superglue. You can use a piece of saran wrap or clear tape to cover this ribbon.

Be sure to apply the non-sticky side of the tape towards the printhead; otherwise, if the printhead comes in contact with the glue on the tape, it may permanently damage the printhead. Next, place the first piece of tape on the printhead with the sticky side facing up. Then, use two more pieces to secure the protective piece to the cartridge body, wrapping one piece around the bottom and one piece around the side.

Step 2

Use a utility knife to cut the top. Starting from the edge, use the edge as a pivot, pushing the knife up and down. Once the edge is open, you’ll work on the other edges. Combine the cutting with a bit of prying.

When all the edges are loosened, the cap can be taken off, exposing the sponge inside. First, it’s essential to write down the color sequence of the cartridge, because HP now makes the same cartridges with different color arrangements, and your cover’s color-coded plug may be different than the cartridge. Next, you need to match the cover with the cartridge.

You won’t take the sponge out just yet, because you’ll need it to protect the printhead from dirt and debris from the sandpaper.

Step 3

Use 150-grit sandpaper and sand the top of the cartridge evenly and smoothly. Then, use your knife to remove the resulting debris.

Because you’re eventually gluing an airtight top, it’s crucial to ensure that you sand everything evenly. If there are still shiny parts anywhere on the cartridge, that means it hasn’t been sanded entirely evenly.

But what is done with the internal walls of the sanded cartridge? You’ll use a long-nose plier to remove those four walls. You don’t have to remove the barriers altogether. It will work as long as the ink can flow freely inside the chamber.

Also, be sure to avoid penetrating the square filter on the bottom.

Step 4

Now, wipe or blow out the debris from the top of the cartridge again.

After removing the sponge, it’s suggested that you clean the inside of the cartridge. You can use compressed air or distilled or tap water.

If there’s dried ink on the filter, wash it with water until the filter is clean. After the top is dry, try to fit a cover on the cartridge. Repeat this process until you can insert the cover in one take—remember, you’ve only got one shot to make it perfect, and it has to be airtight, so practice until you can do it while sleepwalking.

Step 5

Because each compartment needs to be sealed airtight, and the inside dividing walls divided into three colors are fragile, you can apply a small amount of superglue to the inner grooves of the cover.

Add some glue horizontally, and a bit more vertically to form a T shape. You’ll want to apply a generous amount of superglue on the rim of the cartridge and the thin, dividing walls separating the compartments.

Step 6

Apply the cover to the superglue and use one of your rubber bands to seal it to the cartridge, wrapping it as tightly as you can.

Then, leave the cartridge to cure according to the recommended glue curing time. For superglue, you’re going to leave it to cure for about two to three hours.

After double-checking the color arrangements once the glue has dried, add ink until each compartment is full. Then, insert plugs to seal the top of the cover.

Step 7

Once you put the cartridge back into the slot, if the printer is working, but the printout is blank or has stripes, that means the printhead is clogged.

In this case, you should be able to place the cartridge on your priming clip, from which you can suck excess ink from the bottom of the cartridge.

The second method for unclogging your printhead is to wrap a wet paper towel around your cartridge, using a vacuum cleaner to help suck ink out from the bottom.

Step 8

There is a new way of unclogging spotless cartridges because all of the color chambers are sealed airtight. If you performed the previous steps correctly, you can blow air into the air hole and push the ink out from the top.

This method is easy and effective for minor clogs. However, for larger clogs in which the printhead is clogged solid, the air pressure will not work. It will either create an ink backflow or blow out the refill plug, so you should only use this method for minor clogs.

You might also want to release the pressure inside the cartridge after blowing air by removing and reinserting the refill plug.

Step 9

If you are dealing with major clogs at this point in the process, you can fill a bowl with a quarter or half-inch of water and allow the cartridge to soak for 20 to 60 minutes.

Then, use a vacuum or priming clip to suck ink out. Repeat this process if you fail to achieve the desired result on your first attempt.

Once you have removed the clogs, you can fine-tune the cartridge with the air-blowing technique. You’ll be able to see the air and the ink coming out from the bottom. Give it a few seconds, and then remove and reinsert the refill plug to release the excess air.

Step 10

Next, you’ll need to clean the electronic ribbon and insert the cartridge back into the printer. You should then do a printhead cleaning using the printer’s cleaning function.

The refilled cartridge should not show the ink level anymore. The printer will work until it thinks that the ink is depleted. Click the “OK” button, or whatever button your device uses for confirmation, to acknowledge the ink depletion and keep using the printer.

The printer should work fully, but still pay attention to the printout. If the color is fading, take the cartridge out and add more ink. If the cartridge prints in stripes, remove it from the printer and unclog it using one of the previous unclogging methods.

If your printer displays warning messages such as “low on ink” or “ink depletion,” click “OK” to bypass it.

You have now made a spongeless refillable HP cartridge. We hope you enjoyed this tutorial! 

Oct 27th 2021

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