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We finally reduced the injection temperature to around 180C, and now got much better results. We also had to increase the gate size to make sure we can fill the mold (which we don't need to preheat). Thanks.

Thanks. I will check the software. Regarding clearance, we consider have one gear adjustable in position, so there should be no need for clearance in the tooth profile. Also, using aluminum and relativeley thin section, there will be some deformation, thus more clearance - we need to take care...

I used a hobbyist gear generator (https://woodgears.ca/gear/index.html). Now I checked the .dxf file, and it seems accurate, the teeth profile is approximated with segments, and I measured there are enough segments to limit the error to less than 0.005mm. Anyway, I am interested in a low cost...

Thanks for the link. Unfortunately not so easy to find documentation on very high PA gears. I tried the animation on my gear designer, and it seems to roll. Here go the screen captures [link omegawatt.fr/paille/gear2.mp4]HighPA_gear_anim[/url] [link...

Application is a wheel hub for a recumbent bicycle (there will be sprokets attached to the ring gear). The idea is to have the crank pass through the hub, above the large inner gear (an alternative configuration is to have the crank pass through the wheel axis, but this makes it positionned too...

Thanks. We noticed that the hinge does not even need hundreds of openings to fail. Just keeping it open (=elongating the material) for enough time will do. This is quite strange, because some time ago, we tested that material against creeping, it elongated a few percent, then did not extend...

Thanks for your suggestions. Indeed, it might be easier to manufacture using a large roller and more standard gear pair. But I forgot to mention another point: there are also other loads: axial and torque (about a vertical axis) - these loads must be handled but it does not matter very much if...

I want to use an inner/outer gear couple to replace a very large ball bearing, mostly radially loaded (it is a wheel hub) Because of the load direction, it seems wise to increase the pressure angle, as it puts the load forces more perpendicular to the tooth surface and also because it increases...

We try to use low pressure injection molding to produce small current sensors (including sensitive windings). The parts have a hinge to make it openable. Using Overtec 5FR, we have quality issues, especially for the hinge. The material is very soft, so we can make the hinge as thick as 4mm, but...