Daily Filament Jams – Spool & Refill Gap Causing Failures

Bambu Filament and Accesories Filament
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Hi everyone,

I run a small 3D printing business where I use Bambu Lab printers to produce and sell my original designs on platforms like Amazon and Shopify. I’ve always used original Bambu parts and filaments, but over the past few weeks, I’ve been facing daily issues with filament jams.

The main problem seems to come from the gap between the refill and the spool. Filament keeps slipping into that gap and getting stuck, causing the printer to throw filament jam errors and stop mid-print. It’s not a one-time issue—it’s happening every single day. Just this morning, I had to throw away a 24-hour print due to another jam.

I’ve checked the setup, reloaded spools properly, and even tried different feeders, but the issue persists across multiple spools. It feels like this is a flaw in the way the refills are seated or designed.

I reached out to customer support, and while they acknowledged the feedback, the response was quite generic. I’m not looking to vent—I’m hoping to see if others are facing the same issue, and whether Bambu is actively working on a fix or redesign. It’s becoming harder to run a reliable business when basic consumables keep failing like this.

Would love to hear if anyone else is dealing with similar problems or has found any workarounds.

Thanks,

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I have not had this issue, yet. But, I slap both sides of the spool hard several times before releasing that last piece of tape near the end. I think this causes the refill to “expand” out towards the sides. It may just be in my head, but it makes me feel better.:laughing:

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It is very common with refills when forgetting to give them a good massage after spool closure.
For non-refill spools, that would be a major quality shortcoming.

Edit: In the refill installation video is a very short section where you can see the operator pushing the filament using his thumbs. That step is often overlooked but actually quite important to prevent the issue you are seeing.
In addition, AMS savers (the ones with a long PTFE or even the cutting head can help further, especially when combined with spool centre dessiccant holders to add weight) from MakerWorld can help.

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Do you have any photos of what you’re talking about? Because when I install a refill on a spool, I don’t have any gap at all. So I’m having a hard time understanding what you mean.

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Those 4 seconds from on 00:57 make all the difference. Don’t be gentle and work the entire circumference.