Cat Wheel - Low Material and Hardware Cost

Summary

I have wanted to print a cat wheel for a long time, but I always run into the same problem: cost! All the wheel designs out there seem to come with some sort of large expense, whether it be the cost of the files, using tons of hardware, or requiring an absolute boatload of filament.

I decided to try and make the most affordable version. The ways I reduced costs were threefold:

1. The files are free! I understand why people have to charge for files, as making and maintaining this stuff takes a lot of effort, and designers deserve to be compensated for their work. I made this for myself, so it didn't cost me anything extra to post it online.
2. Hardware: Many designs I've seen require 80-100+ fasteners. My design uses just 8. Yes, that's right! Only 8 bolts, along with nuts, washers, and bearings. All the hardware can be bought for $30 or less if you shop around. You also don't need roller-skate/scooter wheels*, as they are printed. The large running wheel itself is glued together, eliminating the need for large amounts of screws or bolts.
3. Filament: Many designs I've seen are made to look sleek and modern but end up using a lot of filament. One design I saw used over 9kg! My design is made to be as light and easy to print as possible. The wheel is a simple tongue-and-groove design with a thickness of just 8mm on the track and a reinforcing rim that also acts as the connecting system for the wheel segments. The base is a skeletal frame design that uses very little material while remaining incredibly strong.

Hardware Required:

• 4x M6 x 25mm bolts
• 4x M6 x 50mm bolts
• 8x M6 lock nuts (nylock recommended)
• 16x M6 flat washers
• 8x 608 size ball bearings (can use skate bearings)

Material Usage:

Your material usage will vary depending on your print settings, but this is what I used:

• Running Wheel: PLA = 3.5kg
• Base Frame: PLA = 580g
• Roller Wheel Hubs (x4): PLA = 70g
• Roller Wheel Tires (x4): TPU = 160g
• Roller Wheel Bushings (x8): ABS = 4g

Other Required Materials:

• Carpet, felt, or fabric for running surface
• Contact cement, carpet tape, or spray glue for carpet
• CA glue for assembling running wheel
• (optional) Anti-slip feet for bottom of frame

Print Settings:

• Running Wheel Parts: 3 walls, 15% infill
• Base Frame: 4 walls, 20% infill
• Roller Wheel Hubs: 5 walls, 20% infill
• Roller Wheel Tires: 3 walls, 100% infill** 
• Roller Wheel Bushings: 3 walls, 100% infill

Printed Parts Quantities:

• Running Wheel Track Sections: 12
• Running Wheel Rim Sections: 24
• Roller Wheel Frames: 2
• Base Frame Cross Brace: 1
• Roller Wheel Hubs: 4
• Roller Wheel Tires: 4
• Roller Wheel Bushings: 8

Overall Dimensions

• Wheel Outside Diameter : 1028.2mm
• Wheel Inside Diameter : 971.8mm
• Running Track Inside Diameter : 992mm
• Total Height: 1039.1mm
• Total Width: 1028.2mm
• Total Depth: 195mm

Notes

• *Roller Skate Wheels: A user on Printables said 63mm Roller Skate Wheels will fit. I have not confirmed this myself so try at your own risk.
• **Additional Tire Print Settings: for best results when Printing tires I recommend using Concentric Patterns for Infill and Top/Bottom Shells. I also Recommend printing tires one at a time or Using print by object to prevent stringing.

Addons/Accessories:

• Shroud for Base

Running Wheel Assembly

Base Frame Assembly

Roller Wheel Assembly

ATTENTION!

Use at your own risk! By downloading and/or recreating these files, you agree that the original creator accepts no liability whatsoever for injury, death, or damage to persons, pets, or property caused directly or indirectly by the use of these files for any purpose.