With over 25 million subscribers across their combined channels, Linus Media Group (LMG) is one of the largest technology-focused YouTube channels in the world. Led by Linus Sebastian, they’re known for their in-depth reviews and bold projects. With a team of over 100 people producing more than 45 videos across all channels each month, they’re constantly coming up with new ideas and pushing creative boundaries. But what you don’t always see in their videos is how much they rely on 3D printing – it’s an essential part of their workflow, involved in most aspects of their operations, from making custom content for the Linus Tech Tips channel to their famous merchandise.

Located just outside Vancouver, LMG’s headquarters are spread across multiple warehouses. Alex Clark, a familiar face from their Linus Tech Tips and ShortCircuit channel, gave us a behind-the-scenes tour, taking us through more than ten shooting sets and backstage – all designed to streamline production – including “fake” kitchens, living rooms, workspaces or even housefronts. And, of course, a greenscreen for all-digital production.

“It’s all about efficiency,” Alex explains. “When you come to shoot, everything is ready. You can just focus on performance.”

The sets buzz with activity: while one scene is filmed, another is being prepped for the next shooting, and a detailed b-roll is captured nearby.

As Alex showed us around, he pointed out countless examples of 3D printing at work. “See those custom security camera holders? 3D printed. The grips on the anti-noise panels? PETG.”

The same goes for the processor cases, for their b-roll shots – 3D-printed.

We even caught up with Linus himself mid-shoot. “This giant screwdriver here, it was printed on a Prusa, motherf*cker!” he delivers a punch.

The Creator Warehouse

Across the street lies LMG’s Creator Warehouse, where the “magic” (hard work) behind their merchandise happens: here, all t-shirts, backpacks, and LTT screwdrivers are created. Tynan Stack, senior mechanical engineer and shop supervisor, walked us through their design and prototyping process.

“Every project usually starts on an FDM printer,” Tynan explained. “It’s quick, cost-effective, and gives us a part we can hold, feel and test. From there, we might move to SLS or SLA printers for higher detail or materials closer to the final product.”

Their arsenal of tools includes optical measurement devices, SLA systems, and a suite of 3D printers, including several Original Prusa MK4S machines.

“The reliability and flexibility of Prusa machines are huge for us,” says Tynan. “They handle everything, from everyday prototypes to flexible materials other printers struggle with.”

Original Prusa 3D printers remain his first choice when it comes to larger projects.

“Automatic bed leveling, Input Shaper for speed, and the extrusion system allow us to print various materials more consistently,” Tynan names his favorite features.

The Workshop and Testing Lab

LMG’s workshop is like a huge laboratory featuring workstations dedicated to testing and prototyping. From custom testing rigs like robotic keyboard testers and high-speed mouse fixtures to force testers with 3D-printed brackets. Basically, anything you need to do real in-depth testing.

Then there are the “fun toys,” like an industrial CT scanner and a Quiet Chamber by RaymondEMC – each providing new ways to test everything from 5G signal interference to product durability.

Among these tools, we found the Original Prusa SL1 resin printer, their first-ever SLA system. It also played a key role in prototyping the LTT screwdriver, providing exact prototypes of certain parts.

Memories of COVID-19

LMG’s story with Original Prusa 3D printers goes back years to the COVID-19 pandemic. Alex shared a memorable story from that time: “In 2020, we got a huge print farm of Prusa kits. The plan was to make this giant statue.”

But life had other plans.

“Right when the printers arrived, everything suddenly got locked down,” Alex remembers. “we used those printers to produce thousands of face shields and mask clips for local communities.”

Does Linus print?

The obvious question – and the answer is yes! He often just shows up and wants something made. Sometimes, he just assigns the task, and sometimes, he wants to be involved in the process and learn how it works.

For Tynan, a 3D printer is a must-have for a modern-day engineer and any kind of workshop.

“If you don’t have a 3D printer in your workshop, you’re missing out,” says Tynan. “It lets you fail fast, fail cheap, and perfect your designs before moving to full production.”

Alex goes even further: “A 3D printer allows you to be a really lazy engineer… and that’s so beautiful.”

But that’s not all. There’s more at LMG than just one Prusa Story! Stay tuned for our second behind-the-scenes look at LMG, where we dive into making their iconic LTT screwdriver – and discover why its signature orange end-cap is more than just a design choice!

Jakub Kmošek and Štěpán Feik