This is a continuation from the conversation about 3D printed pulleys in the “2020 Summer? Swerve” Thread. I want to know how you are pushing your High-performance printer to get every ounce of performance out of it and what has gone wrong for you.
131 used many printed pulleys made from Markforged Onyx material. Some of our smallest pulleys had issues.
The failure mode was Teeth Yielded -> pulley slipped relative to the belt -> pulley melted.
I don’t have a photo of the Falcon/Intake Failure but I do have a photo of the Neo/Climber:
The intake system showed that yielding was the first level of failure with the melting being the second. In once case where we had it happen on the practice field, we managed to stop before everything was melted and we could see teeth rolled over. With the motor shafts in place, there were not many wall thicknesses that made up the pulley teeth and that may have contributed.
What infill % and how many wall layers were used? Also what was the tooth count on the pulley? Curious as I plan to experiment some with 3D printed Onyx pulleys.
We printed with 16 teeth, GT2-3mm.
Here is the geometry of the part:
Here is a cross-section of the part in the middle of the pulley:
Try to ignore the support structure around the teeth when visualizing the pattern.
Onyx, No Reinforcement Material
0.1mm layer height (I probably could have tried again at 0.2mm)
0 degree support angle
Triangle infill (other settings have no impact because it is 100% wall layers in the middle.
4 roofs and floors
I never had a problem with the falcon spline because the part had a lot of engagement with the profile near the outside of the shaft.