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NOTE:2/1/23 Sorry took so long to get back to this. After a lot of testing I have come to the conclusion that a NEMA 23 stepper with an external driver is the way to go to get the torque needed to wind a full spool reliably. So, I am updating the parts list and the files to reflect this. I have left the large and small gears (2:1 ratio) for if you use a Nema 17 for the spool motor, which I do not recommend). I have also posted 1:1 gears for use with the Nema 23.

There are also two aligner arms. One requires a piece of 3/16\" aluminum pipe which fits a piece of PTFE perfectly. Here is a listing for an assortment that I got mine from.

https://www.amazon.com/dp/B07VS4823F?psc=1&ref=ppx_yo2ov_dt_b_product_details

The other aligner is printed but is wider not using the pipe.

There is one more option if people want to drive the spool stepper with a belt you can get these parts and they will mount on the existing shafts and work great, this is what I ended up going to, much quiter. But the 1:1 gears are fine also, just make sure they won't slip.

20 tooth for 6mm belt Pulleys - https://www.amazon.com/gp/product/B077GMKW1C/ref=ox_sc_saved_image_3?smid=A2QQQKMKGVNA5E&th=1

110mm Belt - https://www.amazon.com/gp/product/B09Y8V978K/ref=ox_sc_saved_title_2?smid=A2PX6UKPIQ0VJH&th=1

This is an automatic filament rewinder, It will accept spool diameters up to 210mm as the source and 200mm as the destination. Spool width can be up to about 90mm. This was originally designed for the Bambu Lab X1 Carbon printer's AMS which only accepts up to 200mm spools thus the need for a rewinder. Currently the design is complete and I am assembling the unit.

I have modified Marlin to use a custom menu with only minimal rewinder functions. The spool aligner will sense the spool size (2 endstops, Xmin and Xmax) and sense when the filament runs out (Zmax) so that it can stop and maintain tension on the spool when it completes. I've uploaded a configured version of Marlin 2.0.7.2 that is configured for a Mega 2560 with ramps 1.4 and Reprap Full Graphics discount display. The ramps board only needs the drivers (A4988) installed for X and make sure you set the proper current on them. You will also need an external driver (E) for the NEMA 23 stepper. The slider stepper motor connects to the X driver and the spool stepper connects to the E external stepper driver. The slider alignment endstops connect to the board Xmin and Xmax. The front mounted micro switch is the Xmin and the rear micro switch is Xmax. These micro switches use the common and NC (outside two) connections on the switch and connect to the signal and ground on the ramps. The filament sensor endstop micro switch uses the common and NO connections and connect to the signal and ground on the board's Zmax. You are free to reconfigure Marlin for a different board and display but it has not been tested. Just leave all other settings as configured. Remember this is a modified Marlin so do not try to use a version you download other than this one, it will not work. Any questions about the config just ask.

Here are a couple videos of it running

NOTE: I have updated some of the files since the first iteration. The files are prefixed with Updated_ or New_.

Here are a couple videos of it running

Please refer to the Original model for assembly and any other sources.

I have uploaded the file as a Fusion 360 archive folder so you will need Fusion 360, Fusion 360 is free for a hobby license, to open the file. You may notice some items in the fusion file that I have not posted the files for like the LED light and the spool filament capture bar. These are not needed for the rewinder but were part of my file so I left them. The filament capture bar is still in testing, not sure if it will be a help or not.

Sources for the additional items I've added to the reference design

The design uses mostly an assortment of lengths of M3 Pan head screws, 1- M4 12mm, 8- M4 30mm w/nuts, 5-M3 6mm set screws for the gears. It uses M3 square nuts everywhere instead of inserts. I found inserts got too expensive when you keep reprinting things and have to throw the old prints away with the inserts. So my first item is the M3 square nuts.

https://www.amazon.com/dp/B06XPFLNBS?psc=1&ref=ppx_yo2ov_dt_b_product_details

Power switch receptacle

https://www.amazon.com/dp/B08F331VD2?psc=1&ref=ppx_yo2ov_dt_b_product_details

Cable chain

https://www.amazon.com/Befenybay-Internal-Flexible-Machines-7mmX7mm/dp/B07TGBD2GT/ref=sr_1_1?crid=3BJ0FZ1WG5SL7&keywords=7x7+cable+chain&qid=1667758423&s=industrial&sprefix=7x7+cable+chain%2Cindustrial%2C138&sr=1-1

RAMPS 1.4 (If you don't have one laying around)

https://www.amazon.com/dp/B07ZNFMCSR?psc=1&ref=ppx_yo2ov_dt_b_product_details

ATmega 2560 Arduino board

https://www.amazon.com/ELEGOO-ATmega2560-ATMEGA16U2-Projects-Compliant/dp/B01H4ZLZLQ/ref=sr_1_1?crid=MJI93N5YIZO5&keywords=ATmega+2560&qid=1667758576&sprefix=atmega+2560%2Caps%2C135&sr=8-1

Full Graphics Display

https://www.amazon.com/Aokin-Graphic-Display-Controller-Adapter/dp/B07PF297YD/ref=sr_1_1?crid=UMTWKYOIMVSU&keywords=reprap+full+graphics+controller&qid=1667761390&sprefix=reprap+full+graphics+controller%2Caps%2C154&sr=8-1

Bearings

https://www.amazon.com/dp/B07JJ526NX?psc=1&ref=ppx_yo2ov_dt_b_product_details

NEMA 17 stepper motor (Aligner)

https://www.amazon.com/dp/B00PNEQKC0?psc=1&ref=ppx_yo2ov_dt_b_product_details

NEMA 23 stepper motor (Spool)

https://www.amazon.com/dp/B00PNEPI0A?psc=1&ref=ppx_yo2ov_dt_b_product_details

External Driver

https://www.amazon.com/dp/B07YWZRXGR?psc=1&ref=ppx_yo2ov_dt_b_product_details

Micro Switches

NOTE: I did have one user report that these micro switches take too much force to engage and end up breaking the trigger arm. You may want to source these Omron switches available on DigiKey.

https://www.digikey.com/en/products/detail/omron-electronics-inc-emc-div/SS-5/369869

https://www.amazon.com/dp/B0B7DD5SF1?psc=1&ref=ppx_yo2ov_dt_b_product_details

Power Supply 24v - Main power supply is 24V needed for the external stepper so I've listed a cheap step down buck to get the 12v for the Arduino/RAMPS. It is possible to run some RAMPS boards at 24v but to be safe I used the buck since it is cheap and serves the purpose.

https://www.amazon.com/gp/product/B019GYOM5O/ref=ox_sc_saved_title_7?smid=ATVPDKIKX0DER&psc=1

step down BUCK 24v \u2192 12v

https://www.amazon.com/gp/product/B09LCNVB22/ref=ox_sc_saved_title_5?smid=AE2OZG2NN3099&psc=1

Stepper Coupler

https://www.amazon.com/dp/B085Y6DZJV?psc=1&ref=ppx_yo2ov_dt_b_product_details

M8 200mm Threaded Rod

https://www.amazon.com/dp/B07PQ1487H?ref=ppx_yo2ov_dt_b_product_details&th=1

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