Here are some pictures of last night's trial and error session with the 3d printer. It took me forever to get the support material out from between the ribs. If I had to do an entire pulley (this test was only 3/4" wide) it would be nearly impossible.
Here we have the test part fresh off the printer. You can see all the support material that was put in and how blobby and gunked up it looks.
Here I finally got it all cleaned out, phew. This probably took 15 minutes at least.
