I’ve been trying to print gears for a few projects and have had troubles with warpage on the gear teeth. The gears print nearly perfectly, however the teeth closest to the table that need supports have significant warpage that leads to improper meshing.
This is a second attempt at printing a replacement gear for my RC Car. I thought the black resin might have different printing quality than the clear resin, however both parts came out identical. All of my gear printing attempts have had warpage like this or worse. I suspect It has to do with the supports as the only warped teeth are the ones that start the gear.
This shows the original (bottom left) as well as gears printed in both the black and clear resin. I had manually edited all of the supports in an attempt to make sure every gear tooth had adequate support.
I have written more detail in a few posts on my blog:
Does anyone have suggestions of how to avoid this warpage?