Freemotion Elliptical Roller Wheel Replacement

3D modelled and printed replacement for worn out Freemotion Elliptical

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My Freemotion Elliptical developed a problem - the roller wheel was slipping off the rail, multiple times during a workout, even. This was at least a bit dangerous, and I noticed at least part of the reason was a worn out roller wheel (but also crappy design - short edge not holding the rail very well and a single roller to begin with). After finding a replacement online for well north of $100, I decided I'd try to design/print one myself. I designed the replacement in Fusion 360 copying the original, but also extended the edges to provide a longer arc and allow the wheel to hug the rail better. I used PETG for its flexibility and sturdiness, printed the replacement at 80% infill, bought some 10MM bearings (R10Z), and mounted the new wheel on my elliptical. I'm happy to report it hasn't fallen off the rail yet, and seems to be holding up well through multiple workouts!


STL File for easy printing

Standard Tesselated Geometry - 1.17 MB - 02/14/2018 at 02:32


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B K wrote 03/27/2018 at 14:58 point

I did .3mm for this I believe, at 80% rectilinear fill. I did use supports for the bottom bearing hole, and did not have a fan on. 

I did try 100% infill, but that took forever and the print stuck so hard to my pei glass plate, I ended up destroying the bed and chucking the print with pieces of glass still fuses to it :)

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Filip wrote 03/27/2018 at 14:46 point

What was the layer height and did you use the supports and fan while printing?

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