HydroForge - Hydroponic Station

Grow fresh herbs and small plants (almost) effortlessly with HydroForge, a 3D-printed, automated hydroponic system.

I designed HydroForge to provide a fresh supply of herbs year-round. It's compact, quiet, and stylish—perfect for kitchens and living rooms, and ideal for anyone who loves cooking or mixing cocktails with fresh ingredients. With features like water level control, oxygenation, and an adjustable grow light timer, HydroForge makes indoor gardening simple and rewarding.

💡 If you prefer everything in one place, you can also find all the steps, diagrams, and sourcing info in the downloadable PDF .

For your convenience, a detailed parts list, including quantities and suggested sources with links, is available in the accompanying sheet.

Electronics, Hardware, and Supplies

1. Water pump:Circulates water to your plants.
2. Plastic tube (Ø8mm, 1m): Connects the water pump to the PlantsBox.
3. Water level sensors: Monitors the water levels in the PlantsBox.
4. Water level controller: Automatically maintains the water at the desired level.
5. Air stones: Disperse air from the pump, improving water oxygenation.
6. WiF icontroller: Allows for remote control of the light.
7. Power supply unit (PSU): Provides power to the electronic components.
8. Power plug: Connects the PSU to your main power source.
9. Epoxy resin: Ensures a watertight container, even with potential printing errors.
10. Heat inserts: Provides durable, threaded connections for the 3D-printed parts.
11. Electrical wires and connectors
12. Screws, nuts, and washers
13. Lamp: Provides light for the plants and can be scheduled via the controller. If your station is in a dark area or lacks direct sunlight, invest in a good-quality grow lamp. This will ensure your plants get the light they need for optimal growth.
14. Air pump: Pumpsair into the water to increase oxygen levels. All the noise pollution in the HydroForge comes almost entirely from the air pump. I’ve tested several options, and while this one is the quietest I’ve found (though not silent), it’s worth investing in a better one if noise is a concern.

Growing Supplies

1. Clay Pebbles: Provide a stable medium for plant roots to grow.
2. Rockwool Cubes: To germinate seeds and support young plants.
3. Seeds: Choose the herbs or plants you want to grow.
4. Hydroponic Nutrient Solution: Essential for feeding your plants and promoting growth.

Things to Print

1. PlantsBox: The main container for your herbs.
2. Lid: Features slots to insert hydroponic cups for growing plants.
3. Parting: A divider that separates the plant section from the sensors.
4. Sensors Housing: Two mounts for securely placing water level sensors.
5. Sensors Lid: Covers sensors
6. WaterTower: Holds the water reservoir for your system.
7. Lid: Covers the water tower.
8. Flap: Opens and closes for easy water refilling.
9. Knob:For operating the flap.
10. Electronics Bay:
11. Mounting Plate: For organising and securing the electronics.
12. Lid: A protective cover for the electronics bay.
13. Wall: A second closing plate.
14. Planters (6pcs): Individual cups for plants and growing medium.

Before you start printing, make sure you’ve got the right settings dialled in for optimal results. The goal is to ensure water-tightness. Here’s what I recommend:

1. Material: PETG (excellent layer adhesion, food-safe, significant chemical resistance).
2. Nozzle: 0.6mm for faster prints and durability (wall thickness is 2.8mm).
3. Temperature: Tune your filament, then add 10°C. A little stringing is normal.
4. Layer height: 0.4 mm for a good balance between speed and quality.
5. Infill: Doesn’t matter.
6. Vertical shells: 6
7. Horizontal shells: 6
8. Supports: Not required, nothing to support.
9. Build plate adhesion: Use a brim for long prints (WaterTower and PlantsBox).
10. Cooling: Disabled.
11. Extrusion multiplier: Tune, then add +0.05. The design incorporates slight over-extrusion.
12. Colour: Darker colours absorb more heat in sunlight, raising the nutrient solution's temperature. Plan accordingly!

To ensure your WaterTower and PlantsBox are fully watertight and leak-free, it’s essential to coat the interior surfaces with epoxy resin. Keep in mind that the curing agent (hardener) can release harmful fumes, so it's important to take safety precautions.

1. Prepare the Parts: Make sure both the WaterTower and PlantsBox are clean and dust-free for optimal adhesion.
2. Safety First: Always work in a well-ventilated area and wear a carbon filter face mask to protect yourself from the fumes.
3. Mix the Resin: Follow the epoxy resin packaging instructions for the correct mixing ratio.
4. Apply the Resin: Evenly coat the inside surfaces of the WaterTower and PlantsBox using a brush.
5. Let it Cure: Allow the epoxy to fully cure (typically 24-48 hours)

Install heat inserts into the designated spots using soldering iron. These inserts provide strong, threaded connections for assembling your system securely.

1. Heat the Insert: Using a soldering iron, heat the brass insert.
2. Press into Place: Gently press the heated insert into the designated hole. Make sure the insert is fully seated and flush with the surface.
3. Let it Cool: Allow the heat insert to cool and bond with the plastic before proceeding.

Insert Locations: refer to the images above to see exactly where the heat inserts need to be placed.

Setting the WiFi Timer for Your Grow Lamp

Since the timer is a generic Chinese model, I recommend not connecting it to your home WiFi for privacy and security reasons. Instead, you can create a WiFi hotspot using your phone. Connect the timer to the hotspot, set the desired lighting schedule, and then turn off the hotspot once the settings are saved. The timer will still operate on the scheduled hours without needing a constant connection.

Checking the Water Level Controller

Make sure the XH-M203 water level controller is working properly by testing both sensors. The water pump should automatically turn on when the water level sensor drops to the lower position and switch off when it reaches the upper position in the upper sensor. This ensures your plants always receive the right amount of water without overflowing or running dry.

Now that your Hydroponic Station is set up, it’s time to start planting. The process is simple, and in no time, you'll have fresh herbs growing in your system. Whether you're starting from seeds or transplanting an already-growing plant, here's how to get started:

Planting Process from Seeds

1. Prepare the Clay Pebbles: Wash the clay pebbles thoroughly to remove dust or debris. This ensures a clean environment for your plants.
2. Prepare the Seeds: Place one seed into each rockwool cube and lightly press them in.
3. Add Nutrient Solution: Prepare your hydroponic nutrient solution, but remember to dilute it for the seeds rather than following the package instructions. Place the rockwool cubes in a shallow container and carefully pour the solution over them until they are moist, but not overly saturated.
4. Wait for Roots: Let the seeds sprout and grow small roots, which usually takes a few days to 2 weeks.
5. Transfer to Hydroponic Cups: When the roots are established, place the rockwool cubes into the 3D-printed hydroponic cups. Surround them with clay pebbles, ensuring space for the roots to grow.
6. Place in Hydroponic Station: Finally, insert the cups into your Hydroponic Station. Your station will now do the work of circulating water, nutrients, and oxygen to keep your plants growing strong!

Transplanting Store-Bought or Soil-Grown Plants:

1. Prepare the Plant: Gently remove the plant from the soil, being careful not to damage the roots.
2. Rinse the Roots: Wash off any soil from the roots using lukewarm water. It's important to clean the roots thoroughly to prevent introducing contaminants into your hydroponic system.
3. Place in Hydroponic Cup: Place the cleaned roots into a hydroponic cup with rockwool or directly into clay pebbles, ensuring the plant sits comfortably and the roots have room to grow.
4. Add Nutrient Solution: Prepare the hydroponic nutrient solution.
5. Place in Hydroponic Station: Insert the hydroponic cup with your transplanted plant into the station. The automated system will take care of watering, oxygenating, and feeding your plant.

Stir, Shake, and Savour- Herbs for Cooking and Cocktails!

Do you know what pizza, gin basil smash, shrimp skewers, broth, paella, steaks, and mojitos have in common? My homegrown herbs! That’s right—whether you’re cooking up a storm or mixing your favourite cocktail, these herbs can do it all:

1. Basil: The hero of pesto and star of gin basil smash.
2. Cilantro: Perfect for tacos, salads, or that zesty shrimp dish.
3. Mint: Your mojitos or larb will never be the same.
4. Thyme:Amustforroasts, and steaks.
5. Oregano: Your secret weapon for the best homemade pizza ever.
6. Parsley: From garnish to flavour booster, parsley has your back.
7. Lovage: The secret ingredient for your grandma’s broth recipe.

To keep your herbs happy and healthy, a little regular maintenance goes a long way. Follow these simple tips to ensure your plants continue to thrive in your HydroForge:

1. Top Off the Water: Fill the water tower reservoir every 1-2 weeks and top it off with fresh, cold, nutrient-rich water. Keeping the water level stable helps the plants absorb nutrients properly.
2. Clean the Station: Every few months, it’s a good idea to give the station a full clean. Empty the water, clean out the reservoir, and wipe down all surfaces to prevent algae buildup.
3. Adjust the Light: Keep an eye on your plants' growth. If they seem leggy or pale, they may need more light. Adjust the timer settings or move the light source closer to plants.
4. Prune Regularly: Harvest your herbs often to encourage new growth. Don’t be shy—regular pruning keeps them bushy and productive.

By following these simple maintenance steps, your hydroponic garden will keep producing fresh, flavorful herbs all year round!