How to Convert HP 63 Ink Cartridges to Spongeless Without a Kit

Customer Question:
I’m in Oman and can’t find the refill conversion kit for HP 63 cartridges that includes the top cover. Is it possible to create a spongeless cartridge without the kit by just removing the sponge and refilling the chamber?

Answer:

Yes, You Can Remove the Sponge—But You’ll Need to Rethink the Pressure System

You’re absolutely right: traditional HP 63 cartridges use an internal sponge to hold and regulate ink. When you remove the sponge, the cartridge essentially becomes an open ink reservoir, which creates new challenges in pressure regulation and airflow control.

When a cartridge has no sponge, it becomes more sensitive to leaking, ink starvation, or air bubbles unless you implement a proper one-way air regulation system.

Understanding How Spongeless Cartridges Work

In professional spongeless designs (like the BCH conversion kits), a pressure-regulating valve—usually the white column near the ink intake port—is added. This valve opens when internal pressure drops during printing and closes when idle, maintaining vacuum and preventing leaks or air intake.

If you’re building your own version without a commercial top cover kit, you’ll need to replicate this function using basic materials. Here’s what you can do:

DIY Pressure-Control Alternatives

1. Use a Rubber Plug or Septum:
   After removing the sponge, reseal the cartridge with a soft rubber plug that allows you to inject ink but still seals tight. Make sure there's no open vent where ink can freely leak.

2. Add a Breather Hole with One-Way Film:
   You can create a breather hole and tape it with a piece of air-permeable but ink-resistant membrane (e.g., micropore tape). This allows air in during printing but limits evaporation and ink backflow.

3. Use a Check Valve:
   If you have access to medical or lab supplies, a small one-way check valve (like those used in IV tubes) can be inserted into the vent to allow air in when negative pressure builds up but blocks ink leakage.

4. Keep Cartridge Upright:
   Spongeless cartridges tend to leak more if turned sideways or upside down. Always store and use the cartridge in a vertical orientation—like it would be seated inside the printer.

Things to Keep in Mind

• Start with small ink volumes, especially during testing—around 3–4ml—to prevent pressure imbalance and leaks.

• Prime the cartridge gently after refilling, using a syringe from the bottom outlet, to remove air bubbles.

• If the cartridge leaks or won’t feed ink, it’s usually a sign the pressure system isn’t sealed properly or the venting isn’t working.

Addressing printer issues can be a complicated affair due to the hands-on nature of the problems. So, we're not able to provide remote troubleshooting, suggestions, or support for printer repairs. We offer an in-person evaluation and repair service (https://bchtechnologies.com/printer-repair-service) through our local diagnostic facility. Given the high demand, we operate on a first-come, first-served basis. So, it might take a few weeks before we can get your printer to drop it off. Our services are structured to repair either a whole printer or specific parts, with clear instructions on how to proceed. However, we acknowledge that our rates aren't the most economical. That’s why we encourage people like you—especially international customers—to explore DIY solutions. You can find more insights by visiting our YouTube homepage (https://youtube.com/@bchtechnologies) and searching with keywords like “spongeless HP cartridge” or “HP 63 refill without kit.” Using the search icon next to the "About" tab will help you locate the right videos faster.

Thanks again for your thoughtful question and for being part of our growing global community. We wish you success with your DIY refill project—keep us posted on how it goes!