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Re: pic: 4in Wheel CAD
Press in threaded inserts wouldn't be easy to assemble IMO, and it seems to me that they would spin in the delrin as the bolts are tightened up. It also looks like you have a lot of fasteners not in the model, which will add on a bit of weight.
Maybe think about how you can make the sprocket integral to the structure of the wheel. I would skip on delrin as a wheel material entirely.
What sort of fabrication capabilities are available to you? Perhaps there is a way to take advantage of something unconventional.
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