The Openscad script below allows for the printing of custom spool holders for the Makerbot Replicator. These holders not only allow for different spindle widths and depths but also a different offset from the support holes in the back of the Replicator. You can thus print with different spools than those supplied by Makerbot.

The design allows for printing without support to give as much strength as possible to the spool holders.

Update 5th April 2013:

• Added a new 15mm collar to strengthen bottom of spool holder.
• Added customizer.
• Added recommended print settings.

If you don't want to use Customizer then you need to modify the Openscad script to match your spool. You should be able to start by changing the 2 variables SpoolHoleDiameter and SpoolDepth. The rest of the parameters can be left to begin with. Depending on your print quality you may need to adjust the calculations for the tube baseplate.

Generate your STLs via Openscad. I have found it easier to print the wall support and tube separately. There is an option in the script for this.

The design does not need any support to print. The tube base plate needs to be as flat as possible to slide into the wall support. You may need to sand the base plate edges. It can be a tight fit to begin with and then loosen up a bit. It is possible to snap the tube off trying to extract a stubborn base plate from the wall mount.

The sample STLs are for spool holders which should fit the supplied Makerbot spools.

You will need to mirror the wall support in RepG for the right side spool on the Replicator.

The subtle rounding on the top edges of the wall mount is necessary to allow for easier spinning of the spools.

I have found the following settings work well for printing with Makerware ABS:

Infill: 35%
Layer Height: .27mm
Number of Shells: 2
Feedrate: 80
Travel Feedrate: 100
Raft: yes