K40 Laser engraver/cutter idler pulley

Update - 13th October 2020: Still have this running on my K40 over 3 years later and its working better than the original part.

The pulley idler on my K40's X axis had worn away quite a bit and the belt was popping off every few jobs. I didnt want to wait for a replacement to arrive so I quickly designed this to get me back up and running.

I gave it a larger "lip" to really hold the belt in place.

Remove the bearing, screw, washer and nut from the existing idler and install in this. You might need to use a hammer to lightly tap the bearing in place(and probably the same to remove it from the old idler). I designed it to be tight, but not too tight so it should tap in easy enough.

Probably best to print in nylon or some other hard wearing material, but PLA with 100% infill will be fine if you are just waiting on proper replacement parts to arrive.

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Print instructions

Print Settings

Rafts: No

Supports: No

Resolution: 0.2mm

Infill: 100%

Notes:

Printing at 0.2mm is fine as it's a functional part and doesnt need to be pretty :)