Versaspool Adaptable Filament Spool

Versatile Reusable Spool for Filament Refills

Filament refills are a great idea - re-use the same spool many times and save waste - but it isn't saving the planet if you need to print a new spool each time because refill sizes keep changing.

• Masterspool refills were approximately 102mm internal dia and 47mm wide. Refills that I bought didn't have any cardboard core and worked just fine.

• eSun refills used to be around 92mm dia and 55mm wide. They seem to have changed now.

• Bambu labs and compatibles are about 82mm dia and 60mm wide.

Features

Versaspool uses a lightweight carrier made to fit the refill size. The rest of the parts will accommodate any of the refills above and many more, so at most, for a changed size of refill you should only have to print a new carrier which uses minimal amount of filament. Versaspool adapts to refills with an internal diameter down to 73mm and widths from 40mm to 66mm or more.

The carrier is inserted into your refill then assembled between the two flanges and all held snugly together with a screw-in core. The flanges are keyed with splines to ensure they maintain their orientation. The carrier is also keyed to the flanges and may have a locating peg to engage the hole in the cardboard core used by some refill systems. The screw core can be tightened using your fingers but there is a design included for a tool (shown in green) which can be used for more secure tightening or for undoing locked-up threads.

Flanges have radial slots which align with grooves in the carrier to aid inserting ties for securing a part-used refill before removing it (carriers with diameters near the 73mm minimum may not have room for these grooves).

Flanges have tunnels around the periphery on the inside for holding the filament end. It pushes very easily through the tunnel and threading through a couple of them holds it nicely secure without it projecting outside the spool.

Building

I  have built Versaspool successfully in PLA but it's not the strongest and don't put it in a hot filament drier! Much better to use something tougher and more heat resistant like PETG or ABS, both of which I've also used.

It builds fine with a layer height of 0.2mm and doesn't need supports on my printer. I build with some extra perimeters (4 or 5) and horizontal shell layers (~1mm) for strength - there isn't very much infill.

Dimensions

Versaspool is designed to accommodate a wide range of refill sizes:

• Minimum refill ID is 73mm. There is no maximum although obviously as the ID gets bigger, there is less space for filament.

• Min width between flanges is 40mm. Max is around 70mm.

Carriers built for refills I have used including the first Masterspools are included.

This model has:

• Flange OD = 198mm

• Hub ID = 55mm

• Flange thickness = 4.5mm

The CAD design is parametric and alternative OD, reduced ID, increased flange thickness and other refill sizes are easily generated. If alternative dimensions are required, post a request with reasons and I will likely post extra models.

Testing

I have built and used several revisions. I do not have a Bambu labs refill or printer to test with so haven't tested for full compatibility with AMS but the included carrier fits refills from 3dqf.co.uk. These were measured as 61mm wide and are supposed to be compatible with Bambu and I have gleaned what I can from the web on the necessary dimensions.