We have been 3d printing pulleys for 2 seasons and we are happy with the durability of them. However, we are not sure about the efficiency and couldn’t find a accurate testing method. I have a few questions about this topic and would like to get the other teams opinions.
First of all, what are the suitable materials? We have been 3d printing with PLA since it is easier to print but I want to try other common ones such as ABS and Nylon.
I always tried to maximize the layer height in order to increase the resistance of the parts. However, I believe that it will increase the friction. So what could be the optimal point for a 0.4mm nozzle.
Also, what percentage and pattern of infill is most suitable for pulleys? We mostly use triangle for parts that only get radial load such as pulleys and cubic for the rest of the parts.
Finally, some teams use huge flanges that are probably impossible to print without supports. I think using support material can cause bad layer quality. What can be a good solution to this problem? A few ideas that come to mind is printing the flanges seperately and gluing them and the other is using supports only on the outside of the pitch of the pulley.
I’m also aware that many teams use markedforged printers and don’t bother with the slicer settings too much. However, we only get can print common materials with simple printers .
By the way I am using Cura for slicing the parts.