This thing will create a range of metric and imperial tooth profile pulleys, with any number of teeth, specified in the Openscad file.
Tooth profiles currently supported are MXL, 40DP, XL, H, T2.5, T5, T10, AT5, HTD (3mm, 5mm, 8mm) and GT2 (2mm, 3mm 5mm).
There are a range of editable parameters for editing the fit of the tooth (to account for printer variation), the pulley base, captive nut(s) slot for the set screw, motor shaft diameter, pulley height and belt retainers.
The attached stls are reference pulleys, mostly around the size used on repraps.

Details
After creating the parametric pulley thingiverse.com/thing:11256 I realised this way of modelling them was only going to work for square-toothed pulleys, and a way of producing pulleys for belts with better characteristics for linear motion was required. I found dxf drawings of the relevant tooth profiles here oem.cadregister.com/asp/PPOW_Entry.asp?company=915217&elementID=07807803/METRIC/URETH/WV0025/F and modelled pulley diameter from data here sdp-si.com/D265/HTML/D265T016.html
There were a couple of possible approaches to importing the data, I chose to simplify the bezier curve dxf data in Inkscape, producing vertices with a resolution of around 0.05-0.1mm for each tooth. Another advantage is the the pulleys have the tooth ramp for smooth entry and exit of the belt tooth into the pulley. I'm not really sure 3D printers can take full advantage of this yet, but quality is improving all the time!
If other tooth profiles are required, or you model any, please pass them on to me and I will include them.
Not printed yet... I'm away for the weekend! I'll upload some photos when I do, on Monday.

A standard motor pulley for T2.5 belts. 16 teeth, so works as a drop-in replacement for a 8-tooth T5 pulley.

Some say that this part is a vitamin, but I didn't believe them.

I printed this with 0.35 nozzle, 0.20 layers, 0.36 tracks and 10 secs per layer, with PLA.

Here's a printable pulley for GT2 belts with a 2mm pitch.

Updated using drofart's excellent parametric pulley design here; thingiverse.com/thing:16627/

Probably useful for anyone who doesn't want to customise the pulleys in openscad.

Fewer teeth (More resolution) and smaller hub with two nut traps.

Here is a printable Synchromesh drive pulley for 3.81mm pitch cable with a simple interference fit and 15 grooves. I'm using this on my printers with results just as good a the purchased commercial pulleys. Here's a video:

youtu.be/woZara2NKUc

If you're not familiar with Synchromesh Cable see my other thing:

thingiverse.com/thing:15923

In the future I plan to release a version with a set screw or clamp etc. So far this hasn't slipped for me and I've been printing non-stop for several hours with it.

Easier to print on automated build platform.
Just print this and the standard rims.

To clarify, I only removed the rims from the build tray, I don't think this really even qualifies as a derivative. Useful for me, hope it helps others.

This is an idler pulley for using Synchromesh Cable from SDP/SI ( sdp-si.com/eStore/PartDetail.asp?Opener=Group&PartID=84751&GroupID=768 ) in place of belts for linear motion on RepRap style printers. You can see a video of my Prusa printing with these cables here:

youtu.be/0GMzYMI6rf8

Using this cable and non-printed pulleys gives zero backlash for me and is a nice upgrade from T5 or XL belts. It's also fairly cheap and very lightweight.

This is the T5 pully belt gear for 4mm shaft steppers. Please let me know how it fits your motors. I've only printed it on my prusa which may vary.

Mashed up
thingiverse.com/thing:7218
and
thingiverse.com/thing:5213

Small pulley with snap fit mounting bracket.

Tried to find one on the web but these seem to be really rare. I desinged mine to "run" on a rod for a larger format CNC platform. Works great. Will probably upload one with rounded corners.

Designed in trueSpace and printed on an Up!3d printer.

Over the last couple of months I've read in the forums about people having difficulty with the belts' teeth rubbing on the pulley flanges or fender washers and causing print quality issues. The other night I remembered that flat belts on a crowned pulley will automatically find the center of the pulley. Flanges or fender washers are completely unnecessary!

I consulted my old copy of Machinery's Handbook, 24th edition, and even though it's from the early 1990's, it has a chapter on flat leather belts, how to splice them, how to design pulleys, etc. The quoted rule of thumb is for 1/8" of crown for every foot of pulley width. That would be imperceptible and probably ineffective on a pulley this size. I suspect that recommendation has to do with the geometry and strength of the leather belts.

I took a guess at a 10mm radius crown for the 6mm wide GT2 belt, and it worked great on the first try. This will concentrate the belt tension in a narrow band instead of spreading it across the whole width of the belt, but I think there is more than enough strength in the belt for that.

The belt doesn't track exactly on center due to the various inevitable misalignments of my printer, but it does return to to its happy spot pretty quickly when disturbed.

Video demo on my MakerGear Prusa with GT2 belts: youtube.com/watch?feature=player_profilepage&v=foQmpN2twf8

Files in my GitHub fork of the Prusa Mendel: github.com/DaleDunn/PrusaMendel/commit/f104c989a8dd936e654f2835218a9a53634 58494

One of the things I've been trying to do is print a pulley with a captive nyloc nut. However, the pulleys in PrusaJr's and Greg Frost's github pages, and the ones on thingiverse, all have some problems. Mostly it's that they are not parametric, or not openscad, or just stl, or rely on other files (Prusa's and Greg's) for some reason. So, as a way to get into learning OpenSCAD, I took Giles Bathgate's openscad copy thingiverse.com/thing:3104 of nophead's original thingiverse.com/thing:2079, and the latest one from Prusa's github github.com/prusajr/PrusaMendel mashed them up and tweaked extensively with the following:

• fully parametric, allows any size of pulley base, length of pulley teeth, number of teeth (see note below), number of captive nuts, size of captive nuts and a few other things besides (constants are at the beginning, currently, rather than using configuration.scad)
• new parameters for:
- nut trap shape - allows hex or square nuts to be accommodated
- nut depth - can be edited for different nut types ie nyloc
- pulley base height - can be set to 0 for no pulley base
- pulley base diameter
- pulley teeth height
- number of captive nuts
- angle between captive nuts
• changing motor shaft size doesn't change the shaft cylinder outer dimension (weird mistake?)
• nut trap now parametised with nut size, and is consistent with opening (sides are smooth)
• can have a belt retainer on the open end of the pulley, made with a 45º ramp, to keep wandering belts on the pulley (not tested, can be turned off)
• grub screw hole altered for better printing
• no other file/library dependencies (I thought this was useful as this part often get reprinted on its own)

Update
• parameters for different tooth shape (T5 and XL specified)
• option for T5 or XL pulleys; amend tooth profile parameters and uncomment relevant part for correct tooth spacing
• space between shaft and captive nut is adjustable (triffid_hunter)
• belt retainer height is adjustable (triffid_hunter)

The scad files can be used to create a wide variety of pulleys and toothed idler sprockets, I've made a few different STLs to show, but in the end it's far better to download the scad file and make your own.

Description of included three scad files:
"pulley-T5-8_old_tooth.scad": does NOT have parametric number of teeth, it is fixed at 8 teeth. Everything else is still parametric. The teeth are the same size and spacing as the Prusa/Giles Bathgate/nophead version, which has generally proven reliable.

"pulley-T5-N_old_tooth.scad": you can specify how many teeth you want, however choosing 8 teeth creates a pulley that is slightly smaller (about 0.7mm) in diameter than the Prusa version. The tooth profile is still the same as the original tooth profile from the nophead version.

"pulley-T5-XL-N_tooth.scad": is fully parametric, and uses a tooth profile that is defined by parameters, which allows for T5 or XL shaped-teeth. The tooth shape is subtracted from the pulley, unlike the original version, which is additive. I have included a couple of files for comparison, called "T5-tooth-comparison" scad and stl. The basic difference is that the original version has longer tooth spurs, but the angle of the tooth ramp is incorrect. You can adjust .scad file for deeper teeth, but if there is too much clearance you will get lash from the pulley. The attached STL files are generally sized with a small amount of tolerance, rather than being exact fit. "rtnr" means the pulley has a belt retainer on the end. All pulleys have a 3mm hole for an M3 grub screw, and a slot for a M3 nyloc captive nut. The wall outside of the nyloc nut might be a bit thin for a lot of pressure on the grub screw on the 8-tooth versions.

Regarding tooth spacing: the relationship between the outside diameter of the pulley teeth and the number of teeth is not linear. I took the data for pulley teeth outside diameter from cmtco.com/catalog/tp_mt.html#T5 and sdp-si.com/D265/HTML/D265T016.html put it in Excel and graphed the difference of pulley OD over number of teeth. After a few attempts at manually extrapolating the formula from the curve, I used the trial version of CurveExpert Basic from curveexpert.net/download/ which quickly deduced a formula. This is all shown in the attached excel file. I slightly simplified the formula, added it to the scad file, adjusted the tooth placement and it seems to generate accurately sized pulleys. But the size of the 8-tooth pulley is extrapolated from the end of the curve, and I have nothing to check its diameter is accurate, as 8-tooth pulleys aren't commercially available as it bends T5 belting beyond it's specification. I did the same for XL belt. I can add more variations if there is any interest, eg T2.5, T10, MXL, 40DP, L.
HTD and GT2 belts have rounded teeth, so will require a different method of creating the tooth profile.

Any observations, comments and/or suggestion for additions or further improvement gratefully received.

I'm hoping to use this with dammitcoetzee's pulley: thingiverse.com/thing:10174. I started to make this a derivative but his license doesn't allow derivatives. Honestly, it's not a derivative though because you can use it to mount a lot of things such as Stevewall's excellent block and tackle: thingiverse.com/thing:10549.

Another 40mm pulley to be used with any type of rope. It uses the same wheel as the first one I made. You can hang this one. You also need to use two m4 screws to hold it together.

Ancestry of this object goes back to the first parametric file set for the Mendel, and in particular the Z pulley.

OK if we lived in a perfect world, this thing shoudn't be needed at all. Its intended purpose is to deal with the consequences of the flexing of the motor mounts related to belt tension, above all on the Simplified Prusa Mendel's X axis.

Because of the flexion of the mounts, we get a lack of parallelism of the axes, and the belt wanders on the pulley and gets grossly out of alignment with the carriage.

But why are the motors mounts flexing?

Because plastic-saving design has got the pieces quite thin. Actually excessively thin for their intended function.

So all of this could be easily solved by putting back plastic where it is structurally needed! (and we'll save quite some time and zip ties). Designers, wake up! You have gone too far with some reductions in plastic! We need significantly stiffer mounts for the Y and X motors! (I'll try to help with design, but this will take some time).

Checking old files: Selis Mendel's massive Y bracket was 17.5 mm thick!

So on the interim, to help the belt keep straight, we have this cap (and crummy zip ties and...)

Just a simple pulley for any type of rope. :)

This sprocket is referred to often and referenced to the Rapman Wiki. I put a copy up here in case something happens to the Wiki and the file goes away. It replaces part 10014 and the two stars above/below it. File's origin is here: bitsfrombytes.com/wiki/index.php?title=Spare_parts

The grub screw fell out of my acrylic Z drive sprocket. When reinstalling it, I heard a click... and noticed that the belt would lift up on the sprocket then fall down into the teeth. Tightening the grub screw expanded the acrylic so it wasn't working with the belt properly. I promptly printed the ABS sprocket from this file and am using it now.

I want to build pulley system to drive Prusa Mendel Z-axis using only one dual shaft motor .
I was looking for XL pulley for my Prusa Mendel Z drive.
The only one I found is 10T XL at thingiverse.com/thing:7454
So I build larger XL pulley about the size of NEMA 17 motor

I use SPD/SI's Part Number:A 6Z 3-27SF03708 as my size reference.
sdp-si.com/eStore/PartDetail.asp?Opener=Group&PartID=41873&GroupID=218

I also change the bore size from 1/4" to 5mm and using two M3 nut in the hub

Belt Width 0.375"
Bore Size 5mm
Flange Configuration 1 Flange / With Hub
Pitch Diameter 1.719"
Outside Diameter1.700"
Overall Length 0.813"

Apparently it's hard to find pulleys that turn well. I dunno what kind of load these will handle, but they look neat and the bearing press fits into the pulley nicely (press fitting best done while the plastic is still warm).

If you are missing steps in the X or Y on your Prusa, it could be because the belt is getting caught between the fender washer and the bearing. The best solution is a belt guide such as GregFrost's (http://www.thingiverse.com/thing:8574), but those require you to disassemble your printer before you can install them.

These belt bushings aren't quite as good, but the simply slip over the rod, so you can install them just by loosening a couple nuts. They fill the gap between the bearing and the washer, and are a bit slipperier, so they should help reduce binding.

Inspired by a design by Wilson (http://www.thingiverse.com/wilson).

Replacement gear for the motor side of the extruder of the RapMan 3D printer.
This gear is meant to pair with the original gear of the extruder.
I made this as a replacement for the original gear that broke.

This gear uses the same teeth of the thingiverse.com/thing:4472.
I've placed the nut hole so that the screw will hold the motor on the chamfer instead of the round part of the axis.

Note:
The SolidWorks file was created on version 2008
Note2:
This gear was inspired by ( and made using ): thingiverse.com/thing:4472

printable GT2 x y and z motor pulleys and z rod pulleys

work in progress they print out perfectly on a dimension u-print commercial 3d printer however i do not have my cupcake cnc up and running yet i do not know if they will print out or a makerbot

can some one with a well tuned makerbot with a MK6 stepstruder test print the xy motor pulley and see of they are makerbotable

When I printed the standard pulley from the Prusa git repository, I found that my T5 belt didn't quite fit it and the belt would ride up on the teeth. In response to this, I modified the design iteratively, just printing the tooth portion until I came up with a design that meshed nicely with the Ausxmods T5 belt (http://ausxmods.com.au/t5-timing-belts).

This filament guide pulley allows me to put a CAT-6 box loaded with ABS filament on the floor, run the filament up and over the pulley, and down into the extruder. It is low friction, large diameter and has a deep slot to help guide the filament.

I searched and didn't find one so I downloaded a model from Stock Drive. Then I used Nophead's pulley and a quick mashup of the two to give me an XL 10T pulley with a locking setscrew.

This is a grouping of thingiverse.com/thing:2079 and thingiverse.com/thing:3474 which should take care of all your pulley needs.

Ball chain pulley with matching 608 idler for use with Prusa Mendel instead of using timing belts.

I picked up nylon string ball chain from the craft store at $2.50 for 30yds instead of $2 ft online for the cheapest timing belts you can get.

Actual Ball size is 4mm with 5.3mm length center to center

Simple idler pulley for OpenSCAD. Inspired by a script Rick at Makergear.com wrote. This script is convenient because you can change the belt width and the overhang angle along with the lip height and thickness.



Licensed public domain cause reprappers are chill bros and chicks.

Under the redesign of my custom CNC machine, I'm changing the transmision from threated rod to belt.

This piece will support some pulleys to ensure alignement and tension on the pulley.

Derivative Work from Nophead's and Adrian's Pulleys

Reason: Set Screw can come loose after long prints Cause Poor print quality. Happens In only My X Pulley, why?

Three new Variations to Nophead's Pulley design.
Added feature include:
1) Solidworks History Tree
2) Solidworks Assembly File
3) Replaced M3 nut with Nylon Locking Nut (No more Locktight)
4) Less Chance of Screw Slipping out
5) Nut turned at 60 degrees for better holding strength (Not a plan 5.5mm X 2.5mm Rectangular extrusion hole)
6) Direct Replacement for Nopheads Pulley
7) Thee Flavors to choose from
___A) Single Locknut Pulley
___B) Double Locknut Pulley
___C) Single Locknut Pulley With overzied Locknut hole (experimental)

This sheave rotates on a 624 bearing for free rotation. Allows freedom to put your feedstock anywhere you want it.