Re: 3D Printed Parts on an FRC Robot?
 

You could try using the model of some pulley stock (with the correct tooth count, profile and pitch of course) so that you don't need to draw out the profile in a sketch. Then add whatever bolt holes or bores you need.

Re: 3D Printed Parts on an FRC Robot?
 

Thanks, however part of my motivation is learning how pulleys are designed from the ground up.

Re: 3D Printed Parts on an FRC Robot?
 

It looks like it may be a combination of a lower layer height, high quality filament, and possibly the way the picture is taken. (you could also have the layers start on the inside of the roller to prevent Z-scar from showing)

I'm not saying it isn't vapor smoothed ABS, but there are other ways to get that effect.

Re: 3D Printed Parts on an FRC Robot?
 

Check out the Gates belts and metals design manual. Gates has lots of information about the design of timing belts and pulleys. Also, Gates refers to their pulleys as "metals." Just a little tip to navigate their site.

Re: 3D Printed Parts on an FRC Robot?
 

I can't speak for everyone else, but I do know that Autodesk Inventor has a tool that allows you to generate standard sprockets/gears/pulleys of various sizes and tooth counts.