Idler pulley

A customer came to us with a broken idler pulley from a retro mountain bike. The original part was no longer in production, and finding a replacement meant digging through second-hand spares with no guarantee it would fit or last. We reverse engineered the damaged pulley, focusing on the details that matter: bearing fit, chain alignment, and overall geometry. The goal was to create a replacement that could be produced reliably using FDM 3D printing and hold up under real riding conditions. The new pulley was printed in nylon and fitted with sealed bearings for durability and wear resistance. What started as a simple repair has now become a long-term test. The printed pulley has covered approximately 2,000 kilometres and is still performing as intended, with no failures or unexpected wear. A practical reminder that 3D printing isn’t limited to prototypes. It can be an effective solution for discontinued parts and small-batch functional components. If you have a hard-to-source or obsolete part, we’re happy to review it.