Pulley (1'' inner diameter)

thingiverse

I wanted to print a pulley with my DIY 3D printer and found that printing one single piece was quite challenging. When you have overhanging structures, you either need a support structure or design the part so that it doesn't exceed a 45-degree angle as you move in the z-axis direction. To overcome this issue, I decided to split the part into two separate pieces, making it easier to assemble them afterwards. In my case, I printed a pulley with an inner diameter of about one inch and a maximum outer diameter of 64 millimeters or roughly two and a half inches. Using a mallet, I was able to press the pieces together smoothly, resulting in a sturdy and solid structure that even performed well at 50% infill density.