eSUN Cardboard Spool Swap (no respool)
Print Profile(5)
Description
DESCRIPTION
Have you been frustrated with an eSUN cardboard spool that you want to put straight into your AMS? Instead of respooling it to a plastic spool, I have a quick solution that doesn’t require that respool step.
My solution requires the removal of the eSUN cardboard spool sides, but retaining the internal cardboard hub. The sides are replaced by new 3D printed spool parts that I designed to fit. The 3D printed spool parts press fits into the eSUN cardboard hub and screw together.
The new spool design has been dimensioned specifically for the current eSUN cardboard filaments (two versions), but may work with other brands that fit the same dimensions. For your reference, the current eSUN Cardboard spool dimensions are:
Where ID is the inside Diameter and is either 77.3, 80.4 or 82.0mm.
FRICTION FIT
The new 3D printed plastic spool is a push-fit into the old cardboard hub. The friction fit is important when used in an AMS unit. The spool must be able to effectively rotate the filament, otherwise AMS retraction will fail.
In their wisdom, eSUN has at least two versions of the cardboard spools out there in the wild. Perhaps one will supersede the other and we are in transition? The dimensional parameter that changes is the Inside Diameter (ID), being either 77.3 and 82.0mm. To accommodate the spool variants, I’ve produced a main spool model with ID = 77.3mm and adapter rings to accommodate spools of ID = 80.4 and 82mm.
HOW TO …
Steps to transform an eSUN filament on a cardboard spool to a plastic spool:
- Remove spool side by lifting around the spool edge at various spots. The side panel should come away as one piece; refer to photo “Remove first”.
- There’s an inner cardboard ring (“Remove second”) to remove next. With a little force, this inner ring should just pull out.
- Insert the bottom spool 3D printed part. If there is a visible gap between the printed spool and the cardboard hub, add the required adapter ring. This part is a press fit into the cardboard hub.
- Repeat the cardboard removal process on the spool opposite side.
- Insert the top 3D printed part. This part should screw into the bottom spool part.
THANK YOU
I hope that you can find this print useful, too. If so, you can support my work by buying me a coffee …
Remember to leave a comment, perhaps a like to keep me enthused to make more. I have a 100+ published designs. Do check them out.
PRINTING INFORMATION
There are three print profiles. The first for a main spool with an inner diameter of 77.3mm.
The second print file is for an adapter ring that goes onto my main spool, increasing the inner diameter to 80.4mm, where needed.
The third print file is for an adapter ring that goes onto my main spool, increasing the inner diameter to 82mm, where needed.
My prints are made in 1.75mm eSUN PLA+ Silver filament, with 0.2mm layer height on a Bambu Lab H2D printer.
Both the print profile and the individual STL files are included for download.
If you intend to dry your filament, you should print your new spool in a plastic that can withstand dryer temperatures, for example Polycarbonate (115°C). Note that PLA begins to soften at around 50°C and PETG at 60°C, hence the spools made from these plastics will deform in most hot dryers.
UPDATE
| 07/05/2026 | ISSUE: Top and bottom spools diameter size mismatch (by 1mm). Updated the 3MF and Top spool STL files with revised matching spool diameters. ATTENTION: Use updated files for new spools. Retrofit is optional. |
Q&A
Q: What about these printable plastic rims that clip onto the cardboard spool and they use less plastic? A: My experience with the plastics rims with an AMS has been poor. For a start, the rim is a VERY tight fit. Second, in an AMS, the rim rubs against the AMS case lid. In addition to the extra friction, the friction scores a mark into the AMS lid. |
Q: There are other spools that do the same. Which is better? A: If the replacement spool does not securely attach to the filament, it will not work with the AMS retraction. Instead, the spool will spin, but the filament will not. My spool design is a push-fit to ensure good bonding to the spool. |
Q: Do these spools work in the Bambu Lab AMS? A: These spools fit and work perfectly in a Bambu Lab AMS. |
UPDATE
07/05/2026
License
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