At the scale where your test results are useful (in the thousandths), this must be very sensitive to dimensional inaccuracies. How did you ensure that your printed gears were scaled correctly?
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Originally Posted by ZPrinter 650 hardware manual
You can also employ features like Anisotropic Scaling to adjust for expected shrinkage and bring your parts into true scale. More information on Anisotropic Scaling can be found in the ZPrint™ Software Manual.
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