Storage Solution Using Empty Filament Spools

The Idea Behind This Project:

3D printing has become a popular tool for rapid prototyping and is now accessible to consumers with a budget of $150 or more. However, this increase in 3D printing has unfortunately resulted in a significant rise in plastic waste, with empty filament spools being a major contributor. I have designed a simple storage system to address this issue that repurposes these empty spools. Using Fusion360, I created a stackable, swiveling, and practical storage system that makes use of these spools that would otherwise go to waste.

Where to Find 3D Print Files: (Or feel free to use this as an inspiration and design your storage system)

I’m sorry, but I cannot provide these files for free. I apologize for any inconvenience this may cause. They are available for just $3. You can find them at the provided link. Thank you for understanding. https://www.etsy.com/listing/1668083850/storage-solution-using-empty-filament

Supplies

3D Printing Supplies:

Filaments: PLA, PETG, ABS, or similar types are suitable.
Empty Filament Spools: Any plastic type is acceptable.

Hardware:

Adhesive: CA Glue and Activator are recommended (alternative adhesives may also be used).
Lubricant: Optional, but beneficial for the 3D-printed thrust bearing.

Step 1: Designing the Model: Brainstorming

If you plan on using the files I provided then you can skip to step 4

Envision Your Storage Solution!

Design: What’s the style? Sleek drawers or a rotating base?
Functionality: How does it operate? What are its cool features?
Visualization: Picture the final design or draft it up

When drafting my design I sketched a rough concept using Paint 3D.

Tip: Unleash creativity with AI image generators. DreamStudio generated the second image, however, any AI image generator works. I would recommend using DreamStudio, ImageFX, or DALL-E. Start with this prompt and tweak it to fit your vision. Try it out and see what you can create!

"A cylindrical storage unit made out of empty filament spools as the skeleton, with 3D printed drawers"

Step 2: Designing the Model: Take Measurements

Take Measurements:

Having a clear vision of your storage system makes the measuring process much easier. While measurements will vary according to your unique preferences, keep these key dimensions in mind for a solid foundation. (Refer to the image above for essential measurements.)

Inner Spool diameter (A)
Core diameter (B)
Outer spool diameter (C)
Spool width (D)
Inner spool width. (E)

Step 3: Designing the Model: Prototyping

Design the Prototype:

Use Fusion360, TinkerCad, or any other 3D modeling software and design a functional prototype using the measurements taken. Functionality is key, so prioritize speed over looks. Expect multiple iterations before achieving the final product. The linked storage system files took three to four iterations to perfect, so don't be discouraged if the first one doesn't work.

During the prototyping phase, 3D print key parts of your design to move closer to the final product. Since looks aren't crucial in the prototype, it's better to 3D print the parts quickly. When testing fitment, divide the model using your CAD software or slicer to print only the sections you want to test, saving time and material.

The Final Design:

Once the prototyping phase is over you should have a final design. My final design looked like the following:

Spool Drawer

Step 4: Designing the Model: 3D Printing

3D Printing the Final Design:

Once you have completed all your design changes and iterations, you are ready to 3D print the final design. You can choose the desired quality for the 3D printing. Now that the prototyping phase is over, you can prioritize aesthetics over speed.

3D Print Settings:

The detailed 3d printing settings can be found on Etsy where the files are linked. However here is a basic profile to use:

Material: (PLA, ABS, or PETG)
Layer Height:(.16mm - .24mm) Larger layer height prints faster and lower quality.
Walls: (3 Perimeters)
Support Material: The Balls and Adapter Files need support material.

Step 5: Assembling the Base

Parts Needed:

Swivel Base
Swivel Top
Balls
Stabilizer Cap

How to Assemble (Follow the Order of the Images):

The images show how these parts go together, but here is a brief description.

Insert the Balls into the grooveon the Swivel Base
Place the Swivel Top on the Swivel Base. The top should rotate nicely on the bottom
Glue the Stabilizer Cap onto the pin that sticks through the Swivel Top.

The final image shows a cutout of the pieces assembled. Your model should look similar.

Step 6: Assembling the Spool Drawers

Parts Needed:

Spool
Side A, Side B, and Side C

Assembly:

Before gluing, ensure that all sides are glued together inside the spool to avoid issues placing them in later.

Glue Side A to Side B where the "clip" interlocks.
Glue Side C to Side Aand Side B
Glue all three sides to the spool

All three sides must fit securely inside the spool without any room for movement.

Step 7: More Storage!

I've included several spools in the file packet. However, for some spools, I couldn't measure the inner core diameter, which is crucial for a tight press fit. I've added general adapters for basic spool types, but you may need to tweak the design for a perfect fit.

How to Design Spool Adapters

Measuring: Measure the inner core diameter of both spools you wish to stack together (B in Image 1)
CAD: Create a large, flat plate to act as a spacer for both spools, then create an extrusion on either side using the two measurements taken earlier.
3D Printing: 3D print your custom adapter using support material on one side
Assembly: The adapter fits snugly into the spool's core to prevent movement.

Step 8: Finished Product

The Final Step:

Place the spool assembly on top of the Swivel Top, ensuring a tight fit. Once assembled, you'll have a swiveling and stackable storage system that helps reduce waste by reusing empty spools.

I hope you had a great time working on this project! If you have any questions, comments, or concerns, please don't hesitate to reach out!