Roomba Sweeper Roller

Replacement Roomba sweeper/roller that was inspired by jbruce12000's. I originally tried to use his but ran into issues with just how loud it was on hardwood flooring. Turns out the angle of the brushes does not change across the twist of the roller with his design! Additionally it's very hard and inflexible with my hard TPU. So I thought I'd give it a go from scratch in SolidWorks, and why stop there, how about I design it so that you don't need the 2 foam inserts that are on the original rollers!

This roller is designed to replace the roller itself and the foam cores; so if those are damaged from sweeping up a string, for example, this is a great option. I included 2 versions, a regular and ribbed sweeper, but I've only tested the regular so far. Sweepers are set to a 25 degree angle from pointing straight out.
-tested with Roomba I4
-should work fine with i3, i3+, i4, i6, i6+, i7, i7+, i8, i8+, J7, J8 /Plus, E5, E6, E7, I,E & J Series

-Printed with 98A TPU
-0.2mm layer height
-5% Gyroid infill pattern
-1 wall loop
-0 top or bottom shell wall loops
-5 loops outer brim for secure bed adhesion

You might need to play around with the infill depending oh now soft your TPU is, I recommend 5-10% infill, but start with 5-7% if using 98-95A TPU. Gyroid is important as it gives the best flexibility and support consistency! 0 top/bottom walls and 1 outer wall loops are all important, otherwise the baffle that connects the core to the sweepers will become to inflexible.

Installation instructions:
The original roller has some parts you need to re-use. Pull the grey rolling bearing off the end. Pull the metal nib which is connected to a piece of plastic and pull the whole part out. Move to the other side of the roller and pull out the plastic center rod. That rod might be tough to pull out the first time. Remove the two foam roller inserts.

Print the new roller using TPU settings listed above. The center support inside the roller is keyed, and the keys must line up with the plastic rod. Each of the front and back rollers should be facing a specific way to drag debris into the vacuum. Pay attention to which way they are pointing on the original rollers.

Insert the center rod into the newly printed roller without any of the foam inserts. Make sure the key is lined up and jam it in there until the keys bottom out on the step. Significant force should NOT be required, but firm pressure may. The end of the center rod should be sticking out about 10mm. Add the plastic end piece with the metal nib. Last, add the grey bearing.

Each roller is designed to go in one hole [either square or hex shaped]. Pay attention to which you are replacing. The roller fits both the front or the back equally so this can get mixed up easily.