Custom Spool Adapter for eSun Cardboard Spools

As a user of eSun PLA+ and their latest eSun PLA+HS filaments, I've noticed a switch from plastic spools to more eco-friendly cardboard ones. Although this change is positive, it posed a challenge for compatibility with my AMS. The spool adaptor I found either didn't fit properly or resulted in errors when used with the AMS. Thus, I decided to design a spool adapter that would be a nearly perfect fit.

Optimized for AMS Compatibility

The AMS is designed to support spools with a width of 50-68 mm and a 197-202 mm diameter. This eSun cardboard spool adaptor has a diameter of 200 mm and a thickness equivalent to the Bambu Reusable Spool, ensuring a snug fit within the AMS. Additionally, the adapter maintains a similar weight distribution to avoid balance issues. As you can tighten the adaptor side from both sides, the thickness of the cardboard roll doesn’t matter, as you can tighten the side until pushed against the cardboard.

Design and Usage
This adapter allows for the easy removal of the cardboard layer surrounding the filament. To use it:

1. Carefully Remove Cardboard: Start by gently removing the cardboard from one side of the cardboard spool. It's a swift process, taking only 20 seconds, but requires a gentle hand to keep the filament in place.
2. Attach to Insert: Select the appropriate insert depending on the size of your hub (eSun spools come with varying sizes). I've discovered two common internal dimensions: 76 mm and 82 mm, and designed inserts for both. When you want to print the insert, please remove the size that you do need before pushing the print option. (I suggest printing both, in case the spool you open has the other size internal dimension, and you do not need to wait a couple of hours to print the other one!). This internal part doesn’t need to be an exact fit as the side pushes against the cardboard and holds it tight enough; however, I prefer the tight fitting to remove the chance of an error.
3. Secure and Remove the Other Side: Once the insert with one side of the adaptor is in place and held tight against the filament, flip the spool to remove the opposite side's cardboard.
4. Screw and Tighten: Attach and screw the other side of the adapter onto the insert, ensuring it presses firmly against the cardboard.

The adapter features two holes close to the centre, allowing you to secure the filament's end if needed. It also has two embedded clips in the periphery to fix the tip of the filament if you need to remove it from your printer/AMS for future usage. These clips keep the filament tight in its place.

Material Choice for Durability
I've printed these adapters using eSun PLA+HS, which offers superior strength and toughness compared to standard PLA. I also printed this in bambu PLA and worked well. The pink and yellow ones in the photo are with Bambu PLA.

Customization and Support

If you're using a different brand of cardboard spool with varying internal dimensions, and this adapter doesn't meet your needs, feel free to reach out. I can create files for inserts tailored to other cardboard spool brands. The adaptable design means that the sides are universal; there is no distinction between right and left, and they will tighten anti-clockwise. Please let me know about the internal dimension of the cardboard hub if you reach out.

Happy Printing!