@chrishuck In this instance, it was actually a problem with the slicer settings, and https://wiki.freecad.org/FCGear_TimingGear seems to be okay.
Measuring the tip tip diameter was not a good was to determine proper settings.
Re FreeCAD: luckily not justified this time, but I just wasn't having the confidence that the WB actually produces the exact shape (no references given for the profile construction. https://forum.freecad.org/viewtopic.php?t=35899&start=50 addressed that but link rot set in)
@MisterHW I agree that workbench documentation should contain references to the standards (if any) that the geometry produced is based on. That would certainly help your confidence that model itself is not the problem when troubleshooting. It might be a stretch to have 3d printing specific info for the timing belt pulleys because it’s only one method of production. Printing considerations may not apply to machining.
@MisterHW Shaft fits with 3d printing can be tricky if you’re trying to avoid post processing. I’ve definitely had to reprint things to get what I want after adjusting the model. I’ve found it beneficial to just print a portion of a part to figure out clearances before printing the whole part. Just part of the design process!
@chrishuck That's indeed something I'm no longer fighting (especially since printing in mirror mode on an IDEX usually gives me different results when it doesn't use the same type of filament).
So I clean the holes up with a reamer afterwards. Beautiful results.
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