Lightweight AMS Adapter Wheels for Polymaker Cardboard Spools

Other polymaker cardboard spool adapters out there have the following problems:
1. They fall off
2. They slip during AMS rewinding
3. They are so large that they require you to leave the AMS lid propped open so that they don't rub on the lid
4. They use up too much filament to print a sturdy-enough model to work
5. The variability in Polymaker cardboard spool diameter means plastic rings fit too loosely as often as they fit too tightly.

After lots of frustration with the models available I decided to design one from scratch to try and alleviate all of these issues. After tons of versions and testing, this is (so far) the best one I've come up with. Should work with all Polymaker cardboard spools EXCEPT the PolyTerra series (see note below).

I did my best to shave weight off of this design wherever possible while keeping it fully functional. You have access to all of the holes around the perimeter of the cardboard spool for storing the tail of your filament. The tabs that mount inside the hole of the cardboard spool side are positive enough to hold on tight, but not a bear to remove. The small oval protrusion on the inside of the spool wall transfers the force to the cardboard spool so that no slipping (between the cardboard spool and this adapter) occurs when the AMS is rewinding the spool.

Versions

Version 1

The sides are 2.8mm thick and they have smooth edges along the rolling surface. This has worked well for myself and many others, but some reported lack of traction between these wheels and the drive rollers of the AMS during rewind.

Version 2 [Latest Version] 

Changed two aspects of V1:
1.) Added a toothed texture to the edges to alleviate the issue that some were having with traction.
2.) Thinned down the sides to 2.2mm, saving even more filament (approx 2g).
Thank you to chairmanwon for the feedback and beta testing on this version. 

A Note on PolyTerra Spools

In my testing I have found that these will NOT work with PolyTerra spools. They are slightly wider than other Polymaker cardboard spools and thus with the addition of these adapters, are too wide for the slots in the AMS. I am currently designing a lightweight AMS-compatible reusable spool from scratch that SHOULD allow you to use your PolyTerra filament as a “refill” so that you can still use PolyTerra in your AMS. I will link to that model here in this description once it is published.

Print Settings/Info

Model pictured (V1) was printed with PolyLite PLA through a 0.4 nozzle and using the 0.20mm STANDARD Profile with the following changes made to the profile's default settings:

Sparse Infill Pattern: “Adaptive Cubic”
Brim Type: “No Brim”

Print Weight: 22.74g each (you will need two for each spool) (V2 is slightly lighter than this)
Print Time: 52min each (standard speed) (V2 will take slightly longer to print due to the toothed edges)

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