Y-axis handle weel for mini milling machine

thingiverse

Unfortunately the Y-axis wheel was severely damaged during transportation. Typically a replacement would be machined from high-quality aluminum, however I decided to attempt printing it out of durable plastic instead. Although not the ideal solution, this allowed me to quickly get started using the machine and slightly reduce the repair costs. I chose to reuse the inner part, which includes a limb and a seat on the shaft, and only print the wheel itself. The inner part was carefully milled under precise square conditions before being heated and fused into a plastic wheel. Notably, the cross-section of the aluminum part is 0.5-1 mm larger than the seat in the plastic. To achieve acceptable mechanical strength, the part was printed with six perimeters and fillings of 75%. The combination of ABS, sanding, and acetone made it possible to obtain a smooth surface finish, which reduced contamination during work. This design is intended for use on Rotwerk EFM 200 machines, but should also fit Sieg SX2 models and similar mini milling machines.