Introduction: Design a Parametric Pulley (DXF / STL)

About: Hello, I'm Bruce. I'm a student in Belgium. I have a wide variety of interests: electronics, computers, technology, ... In my spare time I spend a lot of time on: projects, exploring the internet, cycling. ht…

When I needed to make a pulley for a sumo robot I was building. I didn’t quite find the all in one solution I was searching for, I just needed the DXF of a specific tooth profile for a specific number of teeth.

So I could import this in Fusion 360 to make the custom pulley I want.
I found out about a parametric pulley designer on thingiverse but I couldn’t edit them in Fusion 360 to my needs.
I found a workaround on a site: .to export the tooth profile as a dxf.

And I simplified the complete workflow into one scad file. So you could easily generate a custom pulley with a specific: number of teeth, tooth profile and shaft diameter.

Step 1: Opening the File

You can get the latest version of the scad file on my thingiverse

Or you can get the file in this step.

To open the scad file you need to download openscad. Which you can find here for free:

Step 2: Editting the File

Edit the parameters you see in the first three lines.

  • N_tooth = 42; //number of teeth
  • shaft_Dia = 4.2; //shaft diameter in mm
  • profile = 14; //profile options: 1=MXL 2=40DP 3=XL 4=H 5=T2.5 6=T5 7=T10 8=AT5 9=HTD_3mm 10=HTD_5mm 11=HTD_8mm 12=GT2_2mm 13=GT2_3mm 14=GT2_5mm

When you changed the parameters press F6 to render the design.
If you are satisfied with the outcome you can export the file as a DXF.

This DXF can be imported in almost every vector program and cad program: Fusion 360, Autocad, SolidWorks, Inkscape...

In the next step you'll see how I make an example pulley in Fusion 360. But you can stop here if you just need the DXF.

Step 3: Making the Pulley in Fusion 360

This is a step by step photo series of how I made a pulley in fusion 360.
If there is any need for it I'll make a video of this process.