Spoked wheel for a D shaft: parametric template

Parameters

Open in the editor opens the design with these defaults; change them afterwards in Modify › Parameters, and everything that depends on them follows. Opened from the editor’s template library instead (New ▾ › New from template…), the template asks for its values first and checks them against these ranges and against each other, and Copy link gives an address that opens it with your values.

Name	What it sets	Default	Range
`wheelDiameter`	Wheel diameter	60 mm	30 to 150 mm, steps of 1
`wheelWidth`	Wheel width	12 mm	6 to 40 mm, steps of 0.5
`spokes`	Number of spokes	6	3 to 12, steps of 1
`spokeWidth`	Spoke width	5 mm	2 to 12 mm, steps of 0.5
`webThickness`	Spoke thickness	4 mm	1.5 to 20 mm, steps of 0.5
`rimThickness`	Rim thickness	3 mm	1.5 to 10 mm, steps of 0.5
`hubDiameter`	Hub diameter	14 mm	8 to 40 mm, steps of 0.5
`shaftDiameter`	Shaft diameter	5 mm	3 to 8 mm, steps of 0.1
`shaftFlat`	Shaft across the flat	4.5 mm	2 to 8 mm, steps of 0.1
`fit`	Bore clearance	0.1 mm	0 to 0.4 mm, steps of 0.05
`oRingWidth`	Tyre groove width	3 mm	1 to 10 mm, steps of 0.5
`oRingDepth`	Tyre groove depth	1.5 mm	0.5 to 4 mm, steps of 0.25

Notes

The wheel diameter is the bottom of the tyre groove plus the O-ring's cross-section: for a 60 mm wheel with a 3 mm O-ring the tyre is about 63 mm across. Choose an O-ring whose inner diameter is 5 to 10 % smaller than the groove bottom (wheel diameter minus twice the groove depth) so it stays stretched.

Spokes are thinner than the rim and the hub by default (spoke thickness), which saves material and print time; set the spoke thickness equal to the wheel width for a solid web. The spoke width is limited automatically when many spokes would close the windows near the hub.

The bore fits a 5 mm D-shaft with a 4.5 mm flat; the clearance is added to both. TT gear motors have a double-D shaft (5.4 mm with two flats 3.7 mm apart): sketch that on the hub face and cut it instead. Print flat, rim face on the bed.