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Not sure if I've read this thread before, interesting reading your journey in astro. Not sure why you didn't go for Aluminium sprockets in the first place, easily obtainable from many sources as you have probably found out.
3D printers are an interesting invention and can do amazing design work but I find it hard to trust printed plastic for mechanical work where there is some load placed on the printed gears, or whatever. Metals are much more durable for most engineering applications, but I'm old school too ! I have machined many items from industrial plastics and they do their intended job but not for things like gears.
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