Prusament Refill Spool System - Improved

I love Prusament and their refill spools. I tried refilling the spools using the method they suggest (by re-using the injection molded spools) but found that it would not go on properly and wobble while printing. That led me with wanting to print my own spool which I could reuse over and over. 

I tried printing the Official Prusament model. This model is the same model for their prusament spools which are actually injection molded and not FDM printed. I re-mixed this model to better suit FDM printing while keeping the Hexagon style. I also created a labelling system so that you can keep track of which spool is PETG or PLA given there are a lot of the same colours for different types of filament. 

I found the original spool published is decently hard to print given you are printing each hexagon individually which makes your first layer harder to print:

VS

Although it may look like my design uses more filament, it surprisingly uses 2 grams less than the original (using standard 0.20 layer profile). 

My design also makes it easier to remove the orange tags after assembling the spool.

Labelling system: 

You have 2 options for spools, the one where you can add labels by gluing or using tape. The other is for using 5x2 mm magnets. If you decide to do the magnet version I suggest printing the label first to see if the tolerances work for you. The holes are 5.05mm, printing with a stock Prusa MK4S I was able to press fit the magnets in without glue.

Print Instructions

Spool:

• 0.20 Layer Height
• 15% Infill
• 2 Perimeters
• 5 layers Top/Bottom
• Gyroid Infill

You could increase to 3 perimeters if you want, I have found 2 perimeters to be working so far. And for the labels I enabled ironing as I found it made the text nicer. 

Happy Printing and enjoy!