1. Project Overview
Smart Desktop Filament Winder
An open-source, low-cost filament winding machine with pitch and filament thickness control.
1.1 Motivation
This project aims to develop a desktop-sized, affordable, and open-source filament winding machine for use in small workshops, Fab Labs, or educational environments. The device automates the winding process and provides real-time control over filament pitch and thickness through a simple user interface and sensor-based feedback.
It is designed to be easily fabricated using common digital fabrication tools including 3D printing, laser cutting, and CNC machining, and assembled using standard hardware components.
1.2 System Architecture
| Subsystem | Description |
|---|
| Winding Axis | NEMA17 stepper motor with beam break sensor for rotation counting |
| Pitch Control Axis | NEMA17 stepper motor driving a carriage via trapezoidal threaded rod |
| Rotation Feedback | Beam break sensor to detect one full spool rotation |
| Limit Switch | Used for pitch axis homing |
| User Interface | OLED display and 4-button menu system |
| Microcontroller | Seeed Studio XIAO ESP32-C3 with Arduino firmware |
| Motor Drivers | 2x A4988 for controlling stepper motors |
| Power Supply | 12V 3A adapter with rocker switch |
| Frame & Housing | Made from 20x20 aluminum profile, laser-cut acrylic, and CNC-milled polycarbonate |
1.3 Bill of Materials (BOM)
Mechanical Components
| Component | Qty | Material | Method | Notes |
|---|
| 20x20 T-slot Aluminum Profile | 4–6 | Aluminum | Cut to length | Main frame |
| M5 T-slot Nuts | ~20 | Steel | Off-the-shelf | Frame connectors |
| M5 Screws & Washers | ~20 | Steel | Off-the-shelf | Assembly fasteners |
| Spool Holder Arms | 2 | PLA | 3D Printed | Mounts spool |
| Linear Carriage | 1 | PLA | 3D Printed | Pitch motion |
| 8mm Trapezoidal Rod | 1 | Steel | Off-the-shelf | Drives pitch axis |
| Trapezoidal Nut (T8) | 1 | Brass/Nylon | Off-the-shelf | Matches threaded rod |
| Coupler (Motor-Rod) | 1 | Aluminum | Off-the-shelf | Connects motor to rod |
| Bearings (608ZZ) | 2–4 | Steel | Off-the-shelf | Rod support |
| 8mm Linear Rod | 1 | Steel | Off-the-shelf | Rail for carriage |
| Electronics Mount | 1 | Acrylic | Laser Cut | Holds PCB & UI |
| UI Panel | 1 | Acrylic | Laser Cut | Holds screen/buttons |
| Enclosure Panels | 3–5 | Polycarbonate | CNC | Protective casing |
| Spool Base | 1 | Polycarbonate | CNC | Bottom plate |
Electronic Components
| Component | Qty | Specification | Notes |
|---|
| Microcontroller | 1 | Seeed XIAO ESP32-C3 | Arduino-compatible |
| Stepper Drivers | 2 | A4988 | Motor control |
| NEMA17 Stepper Motors | 2 | - | Spool and pitch axis |
| Power Supply | 1 | 12V 3A | Wall adapter |
| Beam Break Sensor | 1 | KY-010 / TCRT5000 | Counts spool rotations |
| Limit Switch | 1 | Mechanical | Pitch homing |
| OLED Display | 1 | 0.96\" SSD1306, I2C | Shows UI |
| Buttons | 4 | 6mm tactile | UI navigation |
| Custom PCB | 1 | KiCad | All-in-one control board |
| Header Pins / JSTs | ~20 | 2.54 mm | For connections |
| Wires | 1 set | 22 AWG | Signal/power |
| Heat Shrink | Various | - | Wire protection |