NEW Prusament Spool Frisbee Flying Disc -Long Range Flights

This is a great flying, Frisbee-style disc made using an upcycled NEW Prusament spool component.

Design goals included:

• Strong flight performance

• Comfortable handling — no sharp edges, burrs, or protrusions

• Clean, appealing appearance

Built with a solid, aerodynamically correct bottom—unlike hollow flow-through designs—so it glides longer, stays steady, and carries farther with less effort.

As shown in the video, I’m consistently getting flights of over 110 feet (~33 meters) into the treeline. The assembled disc weighs approximately 227 grams and flies very similarly to the classic Wham-O “heavyweight” Frisbee, designed for wind penetration and long-distance sailing.

I printed mine in PETG using 4 outer walls and 15% infill. The print was done upright with Snug supports.

The Flying Disc Center includes an embossed PRUSA logo at different layer heights.
To achieve a multi-color effect with a single extruder:

1. Slice the model as usual

2. Add pause(s) at the layer(s) where the logo height changes

3. Swap filament colors at each pause

4. Resume printing

For assembly, the Flying Disc Center (spool core) is cemented to the disc body. The Prusament spool itself snaps in with a light press fit, though you may want to secure it with adhesive for added durability. Acrylic cement or CA glue both work well.

It’s a long print, but the result is a great-looking, great-flying disc that’s well worth the time.

This design uses a depleted NEW Prusament spool, or you can download a dummy version here:

Alternatively, I have added a version (.stl) of just one side of the spool.