How Do I Choose the Best Lightweight Pulley?

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  • Written By: Lori Kilchermann
  • Edited By: Lauren Fritsky
  • Last Modified Date: 19 January 2020
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In order for you to choose the best lightweight pulley for a given application, you should consider several factors, such as price, pulling speed and environment. The speed at which the lightweight pulley will turn is critical in relationship to the material that the pulley will be manufactured from. The environment that the pulley will operate in is also going to be paramount in your decision-making process. Another factor that can make the difference in the type of lightweight pulley that will work in your application is the amount of stress or load that the pulley will have placed against it as it is operating. Price is often a major consideration when making a decision as to which pulley is right for your needs.

Speed is one of the most critical factors when choosing a lightweight pulley. Some materials, such as cast aluminum, can break and actually disintegrate at high speeds. This is often caused by harmonics that can damage the casting and cause small cracks to develop around the perimeter of the pulley as it rotates on an axle. If you need to find a lightweight pulley for a very high-speed application, you may want to choose a forged aluminum or a carbon fiber unit to prevent premature breakage and damage to the machine.


The environment that the lightweight pulley will operate in is another critical factor when choosing the best pulley for the job. High heat and extreme cold can both contribute to premature damage in a pulley. The molecular change that occurs at both ends of the temperature scale can wreak havoc on pulleys. Brass pulleys are better for use in extreme temperatures as the brass does not react to temperature as significantly as aluminum or steel. Carbon fiber is another durable choice, however, price will be significantly higher with the carbon fiber unit as opposed to most other metal variations.

Load or stress placed upon your pulley are often the determining factors when it comes to the type of material the pulley is manufactured from. Cast pulleys are often the most brittle, tending to fracture under high loads. The forged aluminum version of a lightweight pulley is typically the strongest of the lightweight metal designs. Beyond a composite pulley, the forged version will commonly provide the best operational strength under load than any other metal lightweight pulley. If cost is of no concern to you, the carbon fiber pulley will provide you with the lightest weight and most strength of any of the pulley designs. At the opposite end of the price scale, cast pulleys are the least expensive, with the forged units coming in at the mid-level range.


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