From Concept to Creation: The Story of Building the Filament Maker TWO

Creating the Filament Maker TWO was no simple refresh; it was a ground-up transformation. What started as a vision to improve on the original Filament Maker ONE quickly became a deep dive into hardware upgrades, new tech, and customized solutions. We weren't just building a machine—we were designing an experience that would empower users with more data, more control, and a whole new level of serviceability.

With a talented team and a touch of "shoot-for-the-stars" ambition, we tackled everything from circuit boards to filament sensors, crafting a machine that’s smarter, stronger, and ready to make a mark in 3D printing. 

Rethinking the Core: Filament Maker TWO Development 

When we began designing the Filament Maker TWO, it was more than just an upgrade—it was a chance to start afresh. With the original Filament Maker, we’d created a solid machine, but there were constraints we’d had to work around. This time, we wanted to rethink everything, pushing the limits of what a filament maker could be. 

With the Filament Maker TWO, each new feature had the potential to influence others, creating a complex web of interconnected components that needed to work seamlessly together. The goal was to level up the machine in every way possible: from data tracking and internal monitoring to improving the precision and repeatability of every extrusion. This wasn’t just about making a machine; it was about building something that could give users a clear view of what’s happening inside, allowing for fine-tuned control and valuable insights. 

Customer feedback was a major driver of our design decisions. We drew insights from support tickets, user surveys, and countless conversations with our customers to ensure we were tackling the real-world challenges they faced. From better data tracking to enhanced repeatability, every feature of the Filament Maker TWO reflects the feedback we received, creating a machine that’s as responsive to user needs as it is robust in its capabilities. 

As the project scaled up, so did our team. Where the first Filament Maker was developed by a core group of a few engineers, the Filament Maker TWO required a team of close to a dozen, including some of the same minds who had worked on the original machine. Scaling up presented its own challenges—suddenly, we were coordinating a larger team, finding ways to work smoothly and align on the project’s ambitious goals. It was a classic case of aiming for the stars; while we may not have reached every goal right away, we’re incredibly proud of the Filament Maker TWO and everything it’s made possible. 

In many ways, the Filament Maker TWO represents the best of 3devo’s journey: listening to users, investing in innovation, and building a machine that’s ready for the future. It’s a powerful step forward for our team and for everyone who’s been part of our community from the start. 

The Brain Behind the Machine: Custom PCBs 

The Filament Maker TWO marks a significant upgrade, not just in hardware, but in its digital “brain.” Unlike the original Filament Maker, which used simple microcontrollers, the Filament Maker TWO is powered by an integrated computer system with custom-built PCBs. This shift enables the machine to be smarter, more capable, and prepared to grow with users over time. 

Our goals for the Filament Maker TWO required more than just a basic PCB update—we needed a board design with the flexibility and power to handle next-level features. So, we chose to build our own boards in-house, ensuring they could handle increased functionality, including a more intuitive interface, filament sensor, and data capture. Each board was rigorously tested to perform across different scenarios, supporting robust data logging and allowing for future remote updates. This enhanced system provides users with more control over their processes and offers detailed insights they can use to refine their setups. 

Data plays a central role in the Filament Maker TWO. The added feature of remote updates means the machine is future-ready, allowing us to push software upgrades and new functionalities as they become available, without requiring hardware changes. This level of adaptability makes the Filament Maker TWO a long-term tool for innovation. This future-proof approach ensures consistency and compatibility with current systems but leaves space for new possibilities.  

Precision in Every Layer: Crafting the Filament Sensor 

Creating the Filament Maker TWO’s filament sensor was an ambitious project. Our team wanted to build a sensor capable of providing precise measurements and real-time feedback, but this wasn’t your typical off-the-shelf setup. Each component of the sensor—from the board to the camera and even the mirrors—was selected and configured by our engineers, with another team member pulling it all together. It was a truly collaborative effort, but it also came with some unique challenges. 

In general, camera manufacturers tend to be cagey about their documentation, and the software support available wasn’t exactly comprehensive. We had to get creative, testing various configurations, adjusting software parameters, and studying documentation from similar devices. Since no one had ever used this specific camera, with this board, in this exact way, there were no established methods to follow. 

To overcome this, our team dove into research, combing through how other projects had used similar technology and even reviewing open-source code for guidance. Without any standardization to fall back on, nearly every aspect had to be customized. We adjusted angles, fine-tuned the mirrors, and worked with our software engineers to create a system that could reliably capture and process filament data. 

The result is a truly custom filament sensor, designed from scratch and optimized for the Filament Maker TWO. While this level of customization was challenging, it allowed us to create a sensor that meets our exact specifications, providing the real-time, high-accuracy data our users need. 

Streamlining Production 

Building the Filament Maker TWO wasn’t just about adding new features or giving it a slicker look—it was a whole new set of challenges. This machine was designed to elevate filament extrusion and recycling capabilities for our customers, but to make that happen, we had to revamp our entire production process.  

When we started work on the Filament Maker TWO, we knew we’d have to rethink our production approach. 3devo is still a tight-knit company, with a compact Production Team that doesn’t have endless resources or space. To make production efficient and scalable, we redesigned our in-house production line to be streamlined and flexible, without compromising the craftsmanship that goes into every machine. This wasn’t just a matter of rearranging workstations; it was a complete overhaul of our space and workflow. 

One big shift was deciding which components we’d build in-house and which we’d outsource. Balancing in-house quality with outsourced efficiency was crucial, especially for a machine that’s both heavier and more complex than the original Filament Maker. With the Filament Maker TWO weighing in heavier than its predecessor, safety became a top priority across the production line. We had to ensure that the space, tools, and sub-assembly flow were organized down to the last detail, leaving no room for hiccups or safety risks. The entire setup—from space allocation to logistics—was designed so each step of production moves smoothly, without interruptions or wasted time. 

Engineered to Last

Scaling up production for the Filament Maker TWO meant more than just speeding up the assembly line. We had a clear goal: cut production time in half. Achieving that required us to rethink our assembly methods and introduce efficiencies wherever possible. Each sub-assembly step was re-evaluated, allowing us to ramp up production without sacrificing the quality or detail we pride ourselves on. 

The assembly process is now built with the future in mind, making it easy to scale as demand grows. Every step is purposeful, from modular components to streamlined workflows, ensuring that each Filament Maker TWO comes together with precision and consistency. The Production Team’s experience has allowed us to develop an assembly process that’s not only faster but also more adaptable to potential upgrades or iterations. 

While production efficiency was a priority, we knew that serviceability had to be at the core of the Filament Maker TWO’s design. Customer feedback guided us in making some big changes to how easy the machine is to service and maintain. Through improved inter-departmental communication, we collected real-world insights from users and translated those into features like the screw removal kit and a simplified die head. We wanted users to feel like the machine fit together as intuitively as a LEGO set—no tricky assembly, just smooth operation. 

We also developed a standardized quality check for each machine, ensuring that every Filament Maker TWO meets our serviceability standards before leaving the floor. A new alignment fixture and clear quality procedures help us deliver machines that are easy to service right from the start. 

Conclusion

The Filament Maker TWO embodies 3devo's commitment to continuous innovation and the needs of our users. This machine is the result of careful planning, collaboration, and an unwavering focus on quality at every stage. From the highly customized PCB system to the smart filament sensor and streamlined serviceability, each feature was crafted to enhance the user experience and support future growth. We see the Filament Maker TWO not just as a product but as a trusted partner for those aiming to push boundaries in 3D printing and recycling. And this is only the beginning of where we can go, together. 

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