Primary process: Sand Casting. The full route, materials, tolerances and design tips for a pulley, with an indicative cost.
Sand CastingPrimary process
CastingFamily
8Route steps
+/-1mmTypical tol.
A pulley is primarily made by Sand Casting. Sand casting pours molten metal into a mould packed from sand around a pattern. When the metal solidifies the sand is broken away and the casting is cleaned up. Below is the full route to make a pulley, the materials it suits, the tolerances to expect and the main design points. The route is free, from the finder.
Step by step
How a pulley is made
The usual route, raw material to finished part. The amber step is where the pulley gets its basic shape.
Alloy and tooling
Choose the casting alloy for the pulley and make the pattern or metal die that forms the cavity.
Sand Casting
Melt the metal and pour it into the mould, then let the pulley solidify and cool.
Tooling Low (pattern) Tolerance ±0.5 to 1.5mm Lead 1 to 3 weeks
Fettling and cleaning
Cut off the gates and risers, grind away the flash, and clean the raw casting.
Machining
Machine the mating faces, bores and datum surfaces to final tolerance: the as-cast surface is too rough for close fits.
Tooling None Tolerance ±0.125mm, to ±0.025mm Lead 1 to 10 days
Hole making
Drill, ream and tap the fixing and functional holes.
Tooling None Tolerance ±0.05 to 0.2mm Lead hours to days
Heat treatment
Stress-relieve or harden the pulley to reach the strength and hardness the design needs.
Tooling n/a Tolerance can distort Lead days
Surface finish
Plate, anodise or powder coat for corrosion resistance and appearance.
Tooling Low Tolerance adds 0.05 to 0.2mm Lead days
Inspection
Check critical dimensions and, for any part that holds pressure, leak-test before it ships.
Need the real cost for a pulley? The free route above is yours. Unlock the full dossier to quote and source it.
Where this process typically lands. Tighter is possible with extra operations like grinding, at higher cost.
Materials
Materials for a pulley
Grade
Why it suits this
Gray iron (GG25)
Cheap, great damping + wear, easy to cast
6061-T6 aluminium
Machinable, weldable, corrosion-resistant
Design
Design tips
General pointers. The full design-for-manufacturing list for a pulley is in the dossier.
Machined from solid billet.Cast near-net then finish-turn at volume.
Tight groove tolerance.Use the standard groove spec.
Cost
What a pulley should cost
At volume, cast then turn; grooving and boring are the machining.
PER-PART COST vs VOLUME
Per-part cost drops as volume spreads tooling and setup over more parts. The exact figures for a pulley at your volume, in your currency, are in the dossier.
MODEL EST.
$25 to 71per part at 1 off
A rough ballpark only. The dossier gives should-cost at your exact volume and currency, with the full breakdown.
GET THE FULL DOSSIER
Everything you need to quote and source it
The free route above is yours. To actually put a number on a pulley and buy it well:
Should-cost at your exact volume in 12 currencies, with the material, processing, tooling and overhead breakdown
Who to source from, typical MOQ and lead time, and the exact RFQ checklist to send
A quote checker that tells you if a supplier quote is fair, and the red flags to watch
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A pulley is primarily made by sand casting. The route is: Alloy and tooling; Sand Casting; Fettling and cleaning; Machining; Hole making; Heat treatment; Surface finish; Inspection.
What does a pulley cost?
It depends on size, tolerance and volume. As a rough ballpark it starts around $25 to 71 per part at 1 off and falls with quantity. The dossier gives should-cost at your exact volume and currency. A model estimate, not a quote.
What material is a pulley made from?
Common choices are Gray iron (GG25); 6061-T6 aluminium.
What is the main process for a pulley?
Sand Casting. Large or complex metal shapes at low to medium volume, where tooling cost must stay low and some surface roughness is acceptable.
See the exact route and should-cost for your part
The free finder maps your part to its process and full route. Pro adds should-cost at your volume, sourcing and an RFQ draft.
