Why Does My Canon PG-445 Cartridge Overflow After Multiple Refills?

Question:
After refilling my Canon PG-445 cartridge several times, I noticed that the ink capacity has dropped to only 1-2 mL per refill, and the cartridge now overflows easily. I made a tiny refill hole in the fifth slot from the top left. My printer is a Canon Pixma MG2540S. What could be causing this issue? Is the cartridge damaged?

Answer:

The issue you're describing is most likely due to sponge fatigue inside the cartridge. Canon's PG-445 (and similar models such as PG-275, PG-245, PG-210, etc.) use an internal sponge to hold and regulate the ink. Over time-especially after multiple refill cycles-this sponge becomes saturated, compressed, or chemically degraded. When that happens, it loses its ability to absorb and evenly distribute ink, leading to:

1. Reduced Ink Capacity: The sponge can no longer hold the same amount of ink, so even a small refill (1-2 mL) causes overflow.

2. Air Blockages: Damaged sponge fibers trap air bubbles, disrupting ink flow.

3. Overflowing or Leaking Ink: Since the sponge can't absorb properly, ink spills out through the vent or print head area.

Unfortunately, this is a natural limitation of sponge-based cartridges after repeated use. However, there are two possible solutions:

• Option 1: Convert It into a Spongeless Cartridge.
  You can permanently fix the issue by modifying your cartridge into a spongeless design using our Modification Kit for Canon Cartridges (https://bchtechnologies.com/products/modification-kit-for-making-spongeless-cartridge-with-canon-pg-210-cl-211-pg-240-cl-241-pg-245-cl-246-pg-243-cl-244-as-rfc-cb2?_pos=1&_sid=588840a68&_ss=r). This eliminates the sponge entirely and allows you to refill larger volumes cleanly and consistently.

• Option 2: Wash and Reuse the Sponge.
  You can remove the sponge completely, rinse it thoroughly with warm water until all ink residue is gone, and reinsert it once dry. This may temporarily restore absorption, but note that the sponge will eventually degrade again and lose effectiveness.

If you'd like a detailed walkthrough, refer to our instructional video "No. 1 Detailed Guide to Refill Canon PG-275 / CL-276, PG-275XL & CL-276XL" (https://www.youtube.com/watch?v=xlgYNcv0O2I&lc=UgyWD6nToSVqCHYNcgt4AaABAg). Although the model differs slightly, the same principles apply to your PG-445 cartridge.

Addressing printer issues can be a complicated affair due to the hands-on nature of the problems. Therefore, we're unable to provide remote troubleshooting or repair support. However, we offer in-person evaluation and repair services at our BCH Technologies diagnostic facility (https://bchtechnologies.com/printer-repair-service). Because of high demand, service is provided on a first-come, first-served basis and may take a few weeks. We can repair full printers or specific parts, depending on your needs. Our rates may not always be the lowest, so we encourage do-it-yourself approaches when possible. You can start by exploring our extensive library of repair and maintenance tutorials on the BCH Technologies YouTube channel (https://youtube.com/@bchtechnologies). Use the search icon next to "About" to look up videos by topic for faster results.

Thank you again for reaching out and for supporting BCH Technologies. Your participation helps us continue sharing practical knowledge and empowering printer users worldwide.