How to Convert HP 60–65 Integrated Cartridges to Spongeless Design Without Damage

Question: Is it possible to convert an HP 60, 61, 62, 63, 64, or 65 cartridge into a spongeless refillable version by drilling a bigger hole and using tweezers to remove the sponge?

Converting HP Integrated Cartridges to Spongeless Refillable Style

The short answer is: Yes, you can use tweezers to remove the sponge through a larger refill hole—but that's only part of the process, and there are some important considerations to keep in mind.

1. Drilling a Larger Hole to Remove the Sponge

You can drill a slightly larger hole on top of the cartridge to access and remove the internal sponge using tweezers or a hooked tool. The sponge in these cartridges (like HP 60–65) is typically packed tightly, and it takes patience to extract it in chunks. Be cautious not to puncture or damage the ink chamber’s internal walls.

Tip: Use a step drill bit and go slowly to avoid cracking the plastic casing or creating plastic debris that could fall inside the chamber.

2. Installing the New Spongeless Cap with Pressure Regulator

Once the sponge is removed, you must replace the OEM (original) top cap with a specially designed refillable top cap that includes a pressure regulator. The original HP cap lacks this mechanism, which is critical in a spongeless setup.

Why is this important?
Without a pressure regulator, ink can flood out of the printhead or fail to flow consistently. The sponge in the original design helps balance internal pressure and ink flow. When that’s removed, the pressure regulator takes over that function in the new cap.

So yes—you’ll need to remove the entire original cartridge cover and install the BCH-supplied refillable cap as part of the conversion process.

3. Cleaning and Flushing

After sponge removal, flush the cartridge chamber with distilled water or cleaning solution to remove residue and foam particles. Let it dry thoroughly before refilling with ink.

4. Refilling and Priming

When refilling, insert ink slowly and make sure to leave a small air gap inside the chamber. Overfilling can lead to leaks or back-pressure. After sealing the cap, gently blot the printhead on a paper towel to confirm ink is flowing properly.

Addressing cartridge conversion can be a hands-on and technical affair. For that reason, we’re unable to provide remote troubleshooting or individualized support for DIY projects. We do, however, offer an in-person evaluation and repair service through our local diagnostic facility (https://bchtechnologies.com/printer-repair-service). Please note that due to high demand, appointments are on a first-come, first-served basis, and there may be a waiting period before your printer or cartridge can be evaluated. While we’re happy to provide physical repairs or part replacements in-shop, we understand our services may not be the most budget-friendly. That’s why we continue to encourage users to pursue self-help through trusted online resources. You can start by visiting our YouTube channel (https://youtube.com/@bchtechnologies). Use the search icon beside the "About" section to find related videos by keyword—this is the fastest way to locate tutorials we’ve made over the past nine years. YouTube may also recommend other helpful content from creators in the printing community.

Thanks again for your thoughtful question and for supporting what we do. We look forward to helping you with your next printer project!