A broken idler gear on a roller door meant it would not operate up or down via the motor mechanism.
With two halves of the gear reverse engineering still wasn't perfectly straight forward to account for wear of the gear over time.
The final product was recreated and then printed in ABS as a test piece, this test piece has been in operation since October 2020. If the ABS breaks it will be replaced with a Poly Carbonate derivative for the additional stiffness.
CAD image of the gear
Checking the mesh between broken and new gears
Update August 2021
The ABS gear has finally failed after nearly a year of use. It has now been re-printed in PA6-CF as a much tougher material.
Failed Gear
Replacement in PA6-CF
