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3D printing a spur gear

You are tasked with 3D printing a spur gear (~20 mm outer diameter, 3 mm thickness) for preliminary low-torque feasibility testing. 

 

  1. How would you orient the part on the printer (explain your reasoning) and roughly estimate how long this would take

    • FDM (PLA; 15% infill; standard layer height: 0.2mm)

    • SLA (Standard formlabs resin: white/grey/black); include post processing time

  2. Identify the key risks associated with each approach (e.g., mechanical strength, surface finish, dimensional accuracy

  3. Suggest minigation strategies

 

Notes:

  • Assume dimensional precision (gear meshing) is moderately important but not critical.

  • Assume that low-torque testing means forces up to 1–2 N·cm on the gear teeth.

  • Include post-processing time (e.g. surface polishing, SLA washing/curing) in your estimates.

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