It is not recommended to 3D print press-fit wheels, because the material is much less robust and does not have as tight of a fit as an injection-molded or machined part. This is a design that attempts to make more reliable 3D printed flywheels using a 6mmx6mm worm gear with a 2mm hole, inspired by mbregg's work here: https://www.thingiverse.com/thing:2769269
The profile of this wheel is similar to Riot, with a 0.5" section of the profile being a concave arc and all sharp points on the contact face filleted. If your printer settings are dialed in correctly, it will fit in a new OFP cage with about 0.02" clearance on the diameter and 0.03" clearance from the floor of the cage.
Outer diameter: 37.6 mm
Root diameter: 33.0 mm
Worm gear fits into the 6mm x 6mm hole and should be glued with plastic welder of some sort.
v2 runs the walls thinner, potentially riskier.
Should print at 80-90% infill for structural integrity, print lower infill at your own risk.
This design has not been tested yet, awaiting worm gears.
v3_10 has multiple improvements: Primarily dart alignment fixes, but also experimentally testing a high envelopment wheel setup.
CADded to fit the 41mm OFP cage with a 10mm radius circular hole. This is numerically less squishing/crush than v2 (which was at 9.5mm with a 42.5mm cage), but compresses the dart at a more ideal pressure angle.
9.5 also takes a 41mm cage but has 9.5mm hole.