This pulley was designed as part of a project looking into the increases in strength and stiffness which can be achieved through using internal channels accommodating fibre reinforcements (carbon is stated, however a variety of other materials may be used, e.g. basalt, kevlar, flax, steel cable). The design process involved analysis of force lines through an unreinforced part, along with topological optimisation to determine the optimum positioning of the fibres. When reinforced with carbon it can be expected for the pulley to fail at approx. 0.8 tonnes or 8000N. Layer Height - 0.2 Material - PLA(Stiffer) or ABS Supports - None if printer bridges well Infill - 25% + To thread the fibres through the channels create a 'nib' of around 3 - 5cm on a length of carbon fibre tow (approx. 1 - 1.5m) using a good super glue (liquid usually works best). Bond the end of the carbon tow which has not been glued to the pulley in the middle of one of the legs and proceed to thread the carbon around the part. To finish, once no more fibres can fit into the channel, cut off the nib ensuring that the end is glued also in the middle of one of the legs - this is a relatively low stress area. Apply epoxy resin or other ensuring that it penetrates all fibres and cure. Designs created alongside Dr. Hadley Brooks. Profile: http://www.researchgate.net/profile/Hadley_Brooks