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It is very easy to cut an internal keyway on a lathe with just a boring bar and a single point cutter.?
Set it up on the toolpost , center it , and then do the cutting by moving the saddle in and out using the handwheel. Similar to a shaper.
After every stroke just advance the cutter incrementally . Once set up, the actual cutting is less than 5 minutes .?
I have cut numerous keyways this way . My biggest one was 1/4 " wide 1" in length, in steel.?
There are a Youtube videos on this method.

My opinion is that a pulley, 3d printed with a home 3d printer will not be strong enough.?

I tend to agree with Cornelius, but it would be interesting to find out for certain. One of the weaker aspects of an FDM part is the bonding between layers. If you were to print the pulley flat it would be prone to separation with a vee belt, and I think heat from the friction of a running belt would cause trouble as well. If I were going to do it, I would use ABS at a minimum, but I think a nylon-based filament and a toothed (timing belt) system would be your best option.?

Thanks. I like this idea. I saw a couple of videos already. I want to try. The main reason for 3D printed was because I have access to good printers and it is fun to make it differently than the usual methods.?

Prasad

I would use ABS because of past experience. I have a Ryobi table top band saw that I had bought when I was newly setting up my hobby shop. I realized that it's blade speed was meant for cutting wood and was too high for metal. I was cutting aluminum but I was losing blades at a high rate. I made an ABS pully and replaced it which brought the blade speed down significantly. I now use bi-metal blades of 1/2" width on it and they typically last 12 months on average.?

Yes, I am familiar with the process involved. However, cutting keyways on a lathe is new to me and will try.

Prasad?