Universal Refill Spool Adapter for eSun Cardboard Spools (78–92mm)
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Turn empty eSun cardboard spools into reusable master spools for eSun & multi-brand filament refills (Ø 78–92 mm).
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## Universal Refill Spool Adapter (Upcycling eSun Cardboard Spools)
Don't throw away your empty cardboard spools! This modular adapter kit allows you to upcycle eSun cardboard spools into fully functional, reusable Master Spools / Refill Holders compatible with eSun refills and various third-party refill filaments.
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### 🧩 How It Works & What to Print
The design uses two universal threaded flanges (caps) and an interchangeable central core (cylinder) to match the inner diameter of your chosen refill spool.
To assemble one complete reusable spool, you need to print:
- 2x Universal End Caps / Flanges Cap_Universal.stl)
- 1x Central Threaded Cylinder of your required inner diameter Cylinder_XXmm.stl)
#### Available Core Diameters:
Included cylinders range from Ø 78 mm to 92 mm (in 2 mm increments):
* 78 mm | 80 mm | 82 mm | 84 mm | 86 mm | 88 mm | 90 mm | 92 mm
E.g. for new eSun refill, the classical Ø 90 mm spool is not valid. I printed Ø 82 mm as the refill cardboard inner diameter has Ø 83 mm
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### ⚙ Recommended Print Settings
- Material: PLA (PETG or ABS/ASA also work great)
- Layer Height: Up to 0.30 mm (Optional: use Adaptive / Variable Layer Height around the thread areas for smooth screwing action. the rest can be printed in height up to 0.6 mm)
- **Perimeters / Wall Thickness:** 1.6 mm total wall thickness:
- 0.4 mm nozzle: 4 perimeters
- 0.6 mm nozzle: 3 perimeters
- 0.8 mm nozzle: 2 perimeters
- **Infill:** 10% Grid (or Gyroid)
- Supports: None needed
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### 🛠 Assembly Instructions
Remove the original cardboard core sides from your empty eSun spool (or separate the cardboard flanges carefully).
Insert the two universal end caps cap through the center of each side.
Screw one cap into the side of the central cylinder until snug.
Introduce the refill through the free side.
Screw the second threaded cap + cardboard side and tighten the refill roll.
Cut the refill zip-ties / straps only after the spool is fully tightened and secured!