Custom Airless Wheel recycling cardboard spool

Take your projects to the next level with this fully 3D-printable airless wheel! Designed for both aesthetic display and real-world applications, this model offers flexibility in material selection and structural performance. Additionally, it promotes sustainability by repurposing a Bambu Lab cardboard spool as part of the wheel’s structure, reducing waste while enhancing strength and stability.

🔹 Print Profiles:

• Aesthetic Print – Use PLA and Silk PLA for a stunning visual effect, perfect for showcasing your prints.
• Functional Print – Print with TPU for real usage, ensuring durability and flexibility in practical applications. For outdoor use, ASA/ABS is recommended for specific components.

🔹 Wheel Composition:

This modular airless wheel consists of 4 distinct sections, each engineered for optimal performance:

1. Tread 🛞

• Designed with a rugged pattern for grip and durability.
• Only one pattern available at the moment, but more may be added in the future!

1. Airless Sidewall 🏗

• This section relies on infill structures to provide flexibility and shock absorption.
• Tested successfully with honeycomb, gyroid, and 3D honeycomb infill at 7% density.
• Recommended infill: Honeycomb for its balance between strength and elasticity.

1. Cardboard Adapter ♻

• Designed to hold a recycled Bambu Lab spool, making use of waste material in a functional way.
• Physics advantage: The spool acts as a rigid core, distributing forces evenly while keeping the wheel lightweight.
• Enhances rotational stability by minimizing flex in the inner structure.
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1. Rim ⚙

• Aesthetic Prints: The rim and cardboard adapter should be printed as a single object.
• Functional Prints: If the wheel is exposed to sunlight or outdoor conditions, the rim should be printed in ASA/ABS for better durability and UV resistance.
• The rim features a central hole, which can be adjusted to fit any axle for compatibility with different projects.

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• 1 - select Generic-Cylinder2 - click “Scale”
• 3 - unselect "uniform scale"
• 4 - Modify X and Y to fit your axle. (don't forget the tolerance)
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