[Tristan Lall]

I don't think you're going to achieve savings trying to develop a process for making replacement rollers. Assuming your team members' labour is worth anything (either in terms of money, or in terms of an alternative activity), you're going to be hard pressed to beat a cost of $160 per year. Plus you'll have to pay for raw materials as well.

If you really want to spend time developing better Mecanum wheels, that's another story. Then the R&D necessary to investigate new methods of roller production will be a good project.

How much mileage do you intend to put on these wheels in a year, anyway? Depending on the team, it could range from hundreds of metres to tens of kilometres.